Reusable diaper compositions

1. A reusable and washable absorptive mat for the absorption, dispersion and retention of a liquid comprising:

a plurality of non-woven layers, of carded and randomly laid viscose rayon fibres having a cross-section of substantially rigid multi-limbed configuration,

said layers stitchbonded in an as laid state, thereby substantially limiting entanglement and breaking of individual fibres, with a thread under limited tension so as to maintain uniformity of the absorptive mat.

2. A reusable and absorptive mat according to claim 1 , wherein the viscose rayon fibres are of a trilobal configuration and have a water imbibition characteristic of from 100 to 345 percent.

3. A reusable and absorptive mat according to claim 2 , wherein the layers are stitchbonded with a polyester thread in rows approximately 2 to 10 rows per inch, each of said rows having from 6 to 200 stitches per inch.

4. A reusable and absorptive mat according to claim 3 , wherein said absorptive mat is pre-shrunk.

5. A washable and reusable pad for the absorption, dispersion and retention of liquids, said pad comprising:

i. an interior layer of hydrophobic material including a receiving surface;

ii. at least one median layer adjacent the interior layer opposite the receiving surface and comprising a plurality of non-woven layers, of carded and randomly laid viscose rayon fibres having a cross-section of substantially rigid multi-limbed configuration;

said layers stitchbonded in an as laid state, thereby substantially limiting entanglement and breaking of individual fibres, with a thread under limited tension so as to maintain uniformity of the absorptive mat, and,

iii. an outer layer of substantially waterproof polyurethane film adjacent the median layer.

6. A washable and reusable pad according to claim 5 , wherein said interior layer, said at least one median layer, and said outer layer are joined only along outer edges thereof.

7. A washable and reusable pad according to claim 5 , wherein said interior layer and said outer layer are joined to form an interior pocket for holding said at least one median layer.

8. A washable and reusable pad according to claim 5 , wherein said viscose rayon fibres include recycled viscose rayon fibres.

9. A washable and reusable pad according to claim 8 , wherein said viscose rayon fibres are blended with between 5% and 40% polyester fibres.

10. A washable and reusable pad according to claim 5 , wherein said viscose rayon fibres are of trilobal configuration and have a water imbibition characteristic of from 100 to 345%.

11. A washable and reusable pad according to claim 5 , wherein said median layer is preshrunk.

12. A washable and reusable pad according to claim 5 , wherein said pad is contoured in an hourglass shape for wearing as a diaper and has a fastener device for securing said pad about a wearer.

13. A method for manufacturing a reusable and washable article for the absorption, dispersion and retention of a liquid comprising:

i. providing a plurality of viscose rayon fibres having a cross-section of substantially rigid multi-limbed configuration;

ii. carding said plurality of viscose rayon fibres,

iii. randomly laying the carded plurality of viscose rayon fibres into a continuous random web structure to form a desired thickness; and,

iv. stitchbonding said continuous random web structure in an as laid state, thereby limiting entanglement or breakage of individual fibres to form an absorptive mat.

14. A method of manufacturing a reusable and washable article according to claim 13 , wherein said viscose rayon fibres are of a trilobal configuration and have a water imbibition characteristic of from 100 to 345 percent.

15. A method of manufacturing a reusable and washable article according to claim 14 , wherein said stitchbonding step comprises stitchbonding with polyester thread in rows approximately 2 to 10 rows per inch, each of said rows having from 6 to 200 stitches per inch.

16. A method of manufacturing a reusable and washable article according to claim 13 , further comprising:

v. subjecting the stitchbonded mat to a heat treatment to reduce shrinkage when washed after use.

17. A method of manufacturing a reusable and washable article according to claim 16 , wherein said heat treatment is at approximately 110° C.

18. A method of manufacturing a reusable and washable article according to claim 16 further comprising:

vi. providing an interior layer of hydrophobic material having a receiving surface, said interior layer adjacent said absorptive mat opposite the receiving surface; and,

vii. providing an outer layer of substantially waterproof polyurethane film adjacent said absorptive mat.

19. A method of manufacturing a reusable and washable article according to claim 18 , further comprising:

viii. adjoining said interior layer, said absorptive mat and said outer layer along the outer edges thereof to form a pad of unitary construction.

20. A method of manufacturing a reusable and washable article according to claim 18 , further comprising:

viii. adjoining said interior layer and said outer layer to form an envelope, said absorptive mat located within said envelope.

21. A method of manufacturing a reusable and washable article according to claim 20 , wherein said article is contoured in an hourglass shape for wearing as a diaper and further providing a fastener for securing said diaper about a wearer.