U.S. patent application number 16/314412 was filed with the patent office on 2019-06-06 for smart absorbent article, components, and process of making.
The applicant listed for this patent is ONTEX BVBA, ONTEX GROUP NV. Invention is credited to Lisa HEIRMAN, Jens HELLMOLD, Alissa IDELSON, Bjorn VAN KEYMEULEN.
Application Number | 20190167489 16/314412 |
Document ID | / |
Family ID | 59070532 |
Filed Date | 2019-06-06 |
United States Patent
Application |
20190167489 |
Kind Code |
A1 |
HELLMOLD; Jens ; et
al. |
June 6, 2019 |
SMART ABSORBENT ARTICLE, COMPONENTS, AND PROCESS OF MAKING
Abstract
A substrate suitable for incorporation into an absorbent article
for automatic detection of wetness events therein, the substrate
comprising a first surface capable of being arranged proximal to a
body facing side of the absorbent article and a second surface
opposite said first surface and capable of being arranged proximal
to a garment facing side of said absorbent article, said substrate
comprising a plurality of sensor tracks disposed on said first
surface and said sensor tracks comprising: at least one central
track extending parallel to a length of the substrate and parallel
to a longitudinal axis crossing a first end and a second end of the
substrate; at least two side tracks extending parallel to the
central track and oppositely arranged such that the central track
extends therebetween; and wetness sensing tracks extending outboard
of said two side tracks, wherein said central track, said side
tracks, and said wetness sensing tracks are in electrical
communication via one or more shortening elements positioned
proximal to said second end and distal from said first end, and
wherein the substrate is connectable to a clip-on data processing
module at a position proximal to said first end and distal from
said shortening elements such to form a closed electrical circuit,
typically for measuring resistance and/or capacitance therethrough.
In an embodiment said substrate consists of a liquid impermeable
backsheet, preferably a breathable liquid impermeable
backsheet.
Inventors: |
HELLMOLD; Jens; (Beckum,
DE) ; IDELSON; Alissa; (Rheinbach, DE) ; VAN
KEYMEULEN; Bjorn; (Zottegem, BE) ; HEIRMAN; Lisa;
(Buggenhout, BE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ONTEX BVBA
ONTEX GROUP NV |
Buggenhout
Erembodegem |
|
BE
BE |
|
|
Family ID: |
59070532 |
Appl. No.: |
16/314412 |
Filed: |
June 13, 2018 |
PCT Filed: |
June 13, 2018 |
PCT NO: |
PCT/EP2018/065645 |
371 Date: |
December 29, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F 13/42 20130101;
A61B 5/0002 20130101; G01N 33/483 20130101; A61B 5/6804 20130101;
A61B 5/6892 20130101; G01N 33/00 20130101; A61B 2562/164 20130101;
A61F 2013/429 20130101; A61B 5/6808 20130101; A61B 2562/029
20130101; A61F 13/15699 20130101; A61B 5/002 20130101; A61F
2013/424 20130101; A61B 5/207 20130101; A61B 2562/043 20130101;
A61B 5/202 20130101; G01N 27/126 20130101 |
International
Class: |
A61F 13/42 20060101
A61F013/42; A61B 5/00 20060101 A61B005/00; A61B 5/20 20060101
A61B005/20; A61F 13/15 20060101 A61F013/15; G01N 27/12 20060101
G01N027/12 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 16, 2017 |
EP |
17176324.6 |
Nov 14, 2017 |
EP |
17201652.9 |
Jun 1, 2018 |
EP |
PCT/EP2018/064392 |
Jun 11, 2018 |
EP |
PCT/EP2018/065406 |
Claims
1. A substrate (1) suitable for incorporation into an absorbent
article (100) for automatic detection of wetness events therein
and/or risk of exudate leakage therefrom, the substrate comprising
a first surface (2) capable of being arranged proximal to a body
facing side of the absorbent article (100) and a second surface (3)
opposite said first surface (2) and capable of being arranged
proximal to a garment facing side of said absorbent article (100),
said substrate (1) comprising a plurality of sensor tracks (101)
disposed on said first surface (2) and said sensor tracks (101)
comprising: at least one feedback track (4) extending along a
length L of the substrate; and one or more exudate sensing tracks
(9) in electrical communication with said feedback track (4),
wherein said feedback track (4) and exudate sensing tracks (9) are
connected in series and wherein the substrate (1) is connectable to
a clip-on data processing module (103) at a position proximal to a
first end (5) of the substrate (1) such to form a closed electrical
circuit.
2. A substrate (1) according to claim 1 further comprising at least
one side tracks (7,8), wherein said feedback track (4), said side
tracks (7,8), and said exudate sensing tracks (9) are in electrical
communication via one or more shortening elements (10) positioned
proximal to said second end (6) and distal from said first end
(5).
3. A substrate (1) according to claim 1 wherein the sensor tracks
(101) comprise an electrically conductive material, and are printed
sensor tracks.
4. A substrate (1) according to claim 3 wherein the printed sensor
tracks (101) comprise a carbon-based ink and/or a conductive
polymer-based ink, wherein the carbon-based ink comprises a
conductive compound selected from the group consisting of graphene,
graphite, nano-carbon-tubes and mixtures thereof, and wherein the
conductive polymer-based ink comprises a conductive compound
selected from the group consisting of polyacetylene, polypyrrole,
polyaniline and copolymers thereof.
5. A substrate (1) according to claim 2 further comprising an
insulating layer (200) adhered thereto and sized to cover the at
least one feedback track (4), said insulating layer (200) adapted
to provide a seal and/or barrier to liquid from coming into contact
with said feedback track (4).
6. A substrate according to claim 5 wherein the insulating layer
(200) comprises the one or more shortening elements (10), such that
the feedback track (4), the side tracks (7,8), and the exudate
sensing tracks (9) are in electrical communication via said
shortening elements (10) when said insulating layer (200) is joined
to the substrate (1).
7. A substrate according to claim 1 comprising at least two
feedback tracks (4) extending parallel to each other, and further
being in electrical communication with each other via one or more
secondary shortening elements (11), said secondary shortening
elements (11) being located distal from the shortening elements
(10) and between said shortening elements (10) and the first end
(5) of the substrate (1).
8. A substrate according to claim 5 wherein at least a substantial
portion of the exudate sensing tracks (9) remains exposed to
liquids and are not covered by the insulating layer (200).
9. A substrate according to claim 1 wherein the exudate sensing
tracks (9) are in the form of a repeating grid and/or pattern along
the length L of the substrate (1) and a dimension substantially
perpendicular thereto, said grid and/or pattern comprising a
plurality of at least partially interconnected resistive members
(301, 302, 303, 304, 305, 306) each having a shape selected from
straight lines; curved lines; wave-like; geometrically shaped;
squares; parallelograms; parallelepipeds; triangles; circles;
ellipses; dots; decorative elements; flowers; butterflies; and
combinations thereof.
10. A substrate according to claim 2 wherein at least one of the
side tracks (7,8) is discontinuous along an axis parallel to the
length L of the substrate (1) such to force a current through the
exudate sensing tracks (9) towards regions proximal to lateral
edges (12,13) of the substrate (1) said lateral edges (12,13)
extending between the first and second ends (5,6) and along the
length L of the substrate (1), wherein at least a portion of the
exudate sensing tracks (9) are further alternatingly directly
connected and disconnected to the respective side tracks (7,8)
along the length L of the substrate (1).
11. A substrate according to claim 1 wherein the exudate sensing
tracks (9) cover a greater surface area of the substrate (1) than
the feedback track (4), and wherein said exudate sensing tracks (9)
extend both in a direction substantially parallel to the length L
and a direction substantially perpendicular thereto.
12. An absorbent article (100) suitable for detecting a wetness
event therein and/or risk of exudate leakage therefrom, said
absorbent article comprising: a liquid impermeable backsheet; a
liquid permeable topsheet; and an absorbent core interposed between
said backsheet and topsheet, wherein said backsheet comprises the
substrate (1) according to claim 1.
13. An absorbent article according to claim 12 further comprising a
removable clip-on data processing module (103) adapted to monitor
and process resistance and/or capacitance data acquired from the
exudate sensing tracks (9), said clip-on data processing module
(103) being connectable to the at least one feedback track (4) and
a portion of the exudate sensing tracks (9) via a slit and/or
pocket on the backsheet enabling an electrically conductive portion
of said module (103) to directly come in electrical communication
with said at least one feedback track (4) and said portion of the
exudate sensing tracks (9).
14. An absorbent article according to claim 12 wherein the
substrate (1) is positioned such that the first surface (2) faces
the absorbent core, and wherein the insulating layer (200) is
joined to said substrate (1) such that a liquid impermeable seal is
formed providing a barrier to exudates expelled by a subject, when
wearing the absorbent article, from coming into direct contact with
the at least one feedback track (4).
15. A process of making an absorbent article according to claim 12
comprising the steps of: providing a liquid impermeable backsheet
and applying a plurality of sensor tracks to a first surface of the
liquid impermeable backsheet; providing an insulating layer (200)
having a width (w), taken along an axis perpendicular to the
longitudinal axis (y-y), being less than a width (W) of said
backsheet, and optionally applying one or more shortening elements
(10) thereto, optionally further applying one or more secondary
shortening elements (11) thereto, adhering said insulating layer
(200) to said backsheet, said insulating layer being sized and
positioned to cover the at least one feedback track (4), to provide
a laminated substrate; providing an absorbent core comprising
absorbent material; providing a liquid permeable topsheet; and
sandwiching the absorbent core between said laminated substrate and
said topsheet.
16. A process according to claim 15 wherein the sensor tracks are
in the form of an electrically conductive ink and the application
step comprises the printing of the sensor tracks onto the
backsheet, wherein the shortening elements (10) and the secondary
shortening elements (11) are in the form of an electrically
conductive ink and the application step comprises the printing of
the secondary shortening elements (11) onto the insulating layer
(200) or backsheet.
17. A substrate (1) according to claim 4 wherein the conductive
polymer-based ink comprises a conductive compound selected from the
group consisting of poly(pyrrole)s (PPY), polyanilines (PANI),
poly(thiophene)s (PT), poly(p-phenylene sulfide) (PPS),
poly(p-phenylene) (PPP), Poly(acetylene)s (PAC), Poly(p-phenylene
vinylene) (PPV), poly(3,4-ethylenedioxythiophene) (PEDOT), and
mixtures thereof.
18. The substrate (1) according to claim 4 wherein the conductive
polymer-based ink comprises poly(3,4-ethylenedioxythiophene)
polystyrene sulfonate (PEDOT:PSS).
19. The substrate (1) according to claim 5 wherein the exudate
sensing tracks (9) remain exposed and are not covered by said
insulating layer (200).
20. The absorbent article (100) according to claim 12, wherein the
absorbent article (100) is a disposable diaper or pant.
Description
TECHNICAL FIELD
[0001] The invention pertains to the technical field of absorbent
hygiene products. In particular, the present invention relates to
an absorbent article for absorbing body fluids and exudates, such
as urine and fecal material. More particularly, the present
invention relates to absorbent garments, such as disposable diapers
or pants for example for babies or adults, which are configured to
collect and contain fecal material and avoid leakage.
[0002] Most particularly the invention pertains to diapers or
pants, components thereof, and process of making, comprising an
exudate detection system capable of automatically providing a
warning to a care giver when the risk of leakage is elevated and
the diaper or pant warn by a subject should be replaced.
BACKGROUND
[0003] Disposable diapers conventionally include a chassis having a
liquid permeable topsheet, a liquid impermeable backsheet and an
absorbent structure sandwiched between the topsheet and backsheet.
The chassis has a front body panel which, in use, extends over the
stomach and front hip area of the user, and a rear body panel
which, in use, extends over the back and the rear hip area of the
user. Each of the body panels has a waist portion such that, when
the diaper is fastened around the waist of the user, the waist
portions provide a continuous encirclement of the user. In order to
fasten the diaper around the waist of a user, a fastening system
comprising fastening tabs is commonly employed. Fastening tabs may
be provided on side panels which extend from lateral side edges of
the diaper chassis.
[0004] Disposable pants have a similar construction but typically
comprise front and back elasticized belts at either end of the
absorbent structure and are sealed together at lateral side seams
to form an underwear-resembling product that can be worn by a
subject by pulling it up over the legs and may be removed either by
pulling it down in the opposite direction or by tearing the side
seams.
[0005] Inherent with the use of such absorbent articles, eventually
one or more wetness and/or exudate events will occur and thus a
need for change of the absorbent article arises. Particularly in
home care and/or institutions, handling elderly with incontinence
problems, knowing when to change the diaper/pant of a patient is
important. Indeed, changing the diapers too early results in
unnecessary cost and waste and changing too late results in further
cleaning costs and time, and uncomfort or discomfort to the
patient. This problem is exacerbated by motion, indeed taking into
account that a subject wearing the article may move into different
positions the saturation thereof and/or risk of leakage may vary
considerably based on the position and time the subject remains in
that position during and/or after one or more wetness/exudate
events.
[0006] Absorbent articles possessing different types of detecting
means are known, and help to alert a user or caregiver to a change
within the article (e.g. a soiling event). Such detecting means
allow the user or caregiver to readily determine whether or not an
absorbent article needs to be changed, without the need for close
inspection or removal of the article.
[0007] Commonly known detecting means which can be incorporated
into absorbent articles are chemical substances which alter their
form or nature upon contact with liquid. For example, an indication
that an absorbent article is soiled can arise from colour changes
or the appearance or disappearance of an element on the absorbent
article. Such technology is known from, e.g. U.S. Pat. No.
5,389,093, WO 04/028403 and WO 05/030084. Such detecting means are
useful in certain situations, but less so in institutions such as
child-care centres, care centres for the elderly or hospitals where
the status of a large number of wearers must be monitored, often by
a limited staff. Determining whether the absorbent article is
soiled or not still requires the wearer to be disturbed, as the
coloured element must still be visible to the caregiver. This often
requires that the wearer be moved, and their clothes removed or
adjusted.
[0008] WO02/47592 describes an article having a status signalling
device for communicating a change in status of a monitored portion.
The signalling device can comprise a sensor located within the
article, the sensor being connected to an external portion located
on the outside of the article. Changes in the status of the article
(e.g. soiling) can be transmitted from the signalling device to a
receiver via an RF link produced by the external portion. The
external portion is included on the outside of the article and is
secured in place, e.g. by hook-and-loop type fasteners. As such, it
can be removed or displaced and is subject to external influences
(e.g. abrasion, moisture, interference by the wearer). Furthermore,
traditional components of the external portion described in
WO02/47592 render it comparatively expensive to produce, which in
turn, renders its disposal expensive and reuse more likely.
[0009] US 2005/0156744 describes a diaper similar to that of
WO02/47592, in which a detachable transmitter is installed on the
outside of the diaper.
[0010] WO02/78513 describes a fluid discharge monitoring apparatus
for a diaper. The apparatus comprises an RF tag which is responsive
to the discharge of fluid into the diaper. There is no discussion
in WO02/78513 as to the nature of the components which are used in
the fabrication of the monitoring apparatus.
[0011] JP 2005000602 describes a wet detecting device in a diaper,
comprising an RF-ID tag. The tag comprises an IC chip, a
communication control section, data storage medium and an
antenna.
[0012] WO 99/33037 discloses a method and apparatus for detecting a
fluid, said method comprising providing one or more oscillators
transmitting electromagnetic energy, providing one or more resonant
circuits receiving electromagnetic energy from the oscillators,
bringing the fluid and the one or more resonant circuits into
contact with each other so that the receptions of the
electro-magnetic energy of the resonant circuits are changed, and
detecting changes of the transmissions of electromagnetic energy of
the oscillators by changes in one or more characteristics thereof
upon the changes in the receptions of the electromagnetic energy of
the resonant circuits. The resonant circuits may consist of coils
having separated windings made of an electrically conducting
material, which may be provided by printing on a substrate. The
resonant circuit(s) may be embedded in a diaper. Thus, WO 99/33037
discloses an absorbent article comprising at least one wetness
detecting means.
[0013] Although electrical detecting means for indicating the
status of an absorbent article have clear advantages over visual
detecting means, they still suffer from the drawbacks of being
expensive, stiff, bulky and difficult to incorporate into the
article during manufacture. In addition, many traditional
electrical components are not readily disposable or degradable.
Traditional components of electrical circuits such as soldered
metal are not compatible with materials such as paper, plastics and
fibrous materials used in modern absorbent articles. Neither are
they compatible with the rapid assembly-line manufacturing methods
used in the production of absorbent articles. As absorbent articles
are primarily intended for single use (i.e. they are disposable),
it would be a great advantage if electrical detecting means were
cheap and readily disposable. There is thus a desire for a
detecting means which can be readily incorporated into an absorbent
article which provides the advantages of electrical detection, yet
which is cost-effective, simple to manufacture and readily
disposable.
[0014] There is also a desire for absorbent articles comprising
detecting means that provide accurate and reliable sensing and that
can be standardized across a range of products and sizes in order
to limit production cost and thus the end cost to the users and
institutions.
[0015] There is further a desire for detections means that further
take into account not only warning when exudate events happen, but
alternatively or in combination provide on-time alerts based on the
risk of exudate leakage from the absorbent article, for example
taking into account the position that the subject is in during
and/or after one or more repeated wetness/exudate events.
SUMMARY OF THE INVENTION
[0016] In a first aspect, the disclosure relates to a substrate
suitable for incorporation into an absorbent article for automatic
detection of wetness events therein and/or risk of exudate leakage
therefrom, the substrate comprising a first surface capable of
being arranged proximal to a body facing side of the absorbent
article and a second surface opposite said first surface and
capable of being arranged proximal to a garment facing side of said
absorbent article, said substrate comprising a plurality of sensor
tracks disposed on said first surface and said sensor tracks
comprising at least one feedback track extending substantially
parallel to a length of the substrate; and one or more exudate
sensing tracks in electrical communication with said feedback
track, wherein said feedback track and exudate sensing tracks are
connected in series and wherein the substrate is connectable to a
clip-on data processing module at a position proximal to a first
end of the substrate such to form a closed electrical circuit,
typically for measuring resistance, impedance and/or capacitance
therethrough.
[0017] In a second aspect, the disclosure relates to a substrate
suitable for incorporation into an absorbent article for automatic
detection of wetness events therein, the substrate comprising a
first surface capable of being arranged proximal to a body facing
side of the absorbent article and a second surface opposite said
first surface and capable of being arranged proximal to a garment
facing side of said absorbent article, said substrate comprising a
plurality of sensor tracks disposed on said first surface and said
sensor tracks comprising: at least one central track extending
parallel to a length of the substrate and parallel to a
longitudinal axis crossing a first end and a second end of the
substrate; at least two side tracks extending parallel to the
central track and oppositely arranged such that the central track
extends therebetween; and wetness sensing tracks extending outboard
of said two side tracks, wherein said central track, said side
tracks, and said wetness sensing tracks are in electrical
communication via one or more shortening elements positioned
proximal to said second end and distal from said first end, and
wherein the substrate is connectable to a clip-on data processing
module at a position proximal to said first end and distal from
said shortening elements such to form a closed electrical circuit,
typically for measuring resistance and/or capacitance therethrough.
In an embodiment said substrate consists of a liquid impermeable
backsheet, preferably a breathable liquid impermeable
backsheet.
[0018] In an aspect, the disclosure relates to an absorbent
article, preferably a disposable diaper or pant, suitable for
detecting a wetness event therein and/or risk of exudate leakage
therefrom, said absorbent article comprising: a liquid impermeable
backsheet; a liquid permeable topsheet; and an absorbent core
interposed between said backsheet and topsheet, wherein said
backsheet comprises a substrate, the substrate comprising: a
plurality of sensor tracks disposed on said first surface and said
sensor tracks comprising: at least one central track extending
parallel to a length of the substrate and parallel to a
longitudinal axis crossing a first end and a second end of the
substrate; at least two side tracks extending parallel to the
central track and oppositely arranged such that the central track
extends therebetween; and wetness sensing tracks extending outboard
of said two side tracks, wherein said central track, said side
tracks, and said wetness sensing tracks are in electrical
communication via one or more shortening elements positioned
proximal to said second end and distal from said first end, and
wherein the substrate is connectable to a clip-on data processing
module at a position proximal to said first end and distal from
said shortening elements such to form a closed electrical circuit,
typically for measuring resistance and/or capacitance
therethrough.
[0019] In an aspect, the disclosure relates to a process of making
an absorbent article comprising the steps of: providing a liquid
impermeable backsheet and applying a plurality of sensor tracks,
said sensor tracks comprising at least one central track extending
parallel to a length of the substrate and parallel to a
longitudinal axis crossing a first end and a second end of the
substrate; at least two side tracks extending parallel to the
central track and oppositely arranged such that the central track
extends therebetween; and wetness sensing tracks extending outboard
of said two side tracks, wherein said central track, said side
tracks, and said wetness sensing tracks are in electrical
communication via one or more shortening elements positioned
proximal to said second end and distal from said first end, and
wherein the substrate is connectable to a clip-on data processing
module at a position proximal to said first end and distal from
said shortening elements such to form a closed electrical circuit,
typically for measuring resistance and/or capacitance therethrough;
providing an insulating layer having a width, taken along an axis
perpendicular to the longitudinal axis, being less than a width of
said backsheet, and optionally applying one or more shortening
elements thereto, optionally further applying one or more secondary
shortening elements thereto; adhering said insulating layer to said
backsheet, said insulating layer being sized and positioned to
cover the at least one central track and the at least two side
tracks, to provide a laminated substrate; providing an absorbent
core comprising absorbent material; providing a liquid permeable
topsheet; and sandwiching the absorbent core between said backsheet
and said topsheet.
[0020] In a further aspect, the disclosure relates to a process of
making an absorbent article comprising the steps of: providing a
first continuous film and applying a plurality of sensor tracks,
said sensor tracks comprising at least one central track extending
parallel to a length of the substrate and parallel to a
longitudinal axis crossing a first end and a second end of the
substrate; at least two side tracks extending parallel to the
central track and oppositely arranged such that the central track
extends therebetween; and wetness sensing tracks extending outboard
of said two side tracks, wherein said central track, said side
tracks, and said wetness sensing tracks are in electrical
communication via one or more shortening elements positioned
proximal to said second end and distal from said first end, and
wherein the substrate is connectable to a clip-on data processing
module at a position proximal to said first end and distal from
said shortening elements such to form a closed electrical circuit,
typically for measuring resistance and/or capacitance therethrough;
providing a second continuous film having a width, taken along an
axis perpendicular to the longitudinal axis, being less than a
width of said first continuous film, and optionally applying one or
more shortening elements thereto, optionally further applying one
or more secondary shortening elements thereto; adhering said second
continuous film to said first continuous film, said second
continuous film being sized and positioned to cover the at least
one central track and at least a portion of the at least two side
tracks (typically said "at least portion" being proximal to a
position where the clip-on data processing module is connected to
said substrate), to provide a laminated substrate; providing an
absorbent core comprising absorbent material and a liquid permeable
topsheet; and sandwiching the absorbent core between said laminated
substrate and said topsheet, to form a laminated assembly;
optionally cutting said laminated assembly at regular intervals to
form a plurality of individual absorbent articles.
[0021] In a further aspect, the disclosure relates to a clip-on
data processing module suitable for removable attachment to an
absorbent article for automatic detection of wetness events
therein, the module comprising: a housing; and a flexible
connection member (though it is understood herein that a stiff
connection member may equally be used as long as mechanically
suitable for, for example, clamping, albeit a flexible connection
may provide some advantages as will be described herein below)
coupled to said housing and having a free end being cantilevered
from said housing, said end comprising one or more electrically
conducting connection ports, wherein the housing comprises therein
a data processing system, said data processing system comprising a
power source, a processor, and a transmitter; and a motion sensor
in electrical communication with at least said processor, the
flexible connection member being arranged to fasten to a surface of
the absorbent article, wherein the absorbent article comprises a
plurality of sensor tracks, and to electrically connect at least
two of said plurality of sensor tracks to said processing system
via said one or more electrically conducting connection ports.
[0022] In a further aspect, the disclosure relates to a kit of
parts comprising a clip-on data processing module as described
herein above; and an absorbent article as described herein above,
and optionally a charging unit adapted to charge a plurality of
clip-on data processing modules at a given time, preferably via
wireless charging.
[0023] In a further aspect, the disclosure relates to a clip-on
data processing module suitable for removable attachment to an
absorbent article for automatic detection of wetness events
therein, the module comprising: a housing; and a flexible
connection member coupled to said housing and having a free end
being cantilevered from said housing, said end comprising one or
more electrically conducting connection ports, wherein the housing
and/or said flexible connection member comprises therein a data
processing system, said data processing system comprising a power
source, a processor, and a transmitter; and a motion (or position)
sensor in electrical communication with at least said processor,
the flexible connection member being arranged to fasten to a
surface of the absorbent article, and to electrically connect at
least one, preferably at least two, of a plurality of sensor tracks
present on a body facing side of a backsheet of said absorbent
article, to said processing system via said one or more
electrically conducting connection ports, and wherein said housing
further comprises an electronic-ink (although preferred due to its
lower power consumption, alternative displays may also be
considered herein such as LCD) based display for displaying textual
and/or graphical indicia, said display comprising: a layer of
electronic ink including a bi-stable non-volatile imaging material
disposed between an activation layer and a transparent electrode
layer located above the layer of electronic ink, for activating the
layer of electronic ink at particular locations to display textual
and/or graphical indicia on the surface of the display, wherein the
layer of electronic ink does not require electrical power to
maintain the indicia visible.
[0024] In a further aspect, the disclosure relates to a substrate
suitable for incorporation into an absorbent article for automatic
detection of wetness events therein, the substrate comprising a
first surface capable of being arranged proximal to a body facing
side of the absorbent article and a second surface opposite said
first surface and capable of being arranged proximal to a garment
facing side of said absorbent article, said substrate comprising a
plurality of sensor tracks disposed on said first surface and said
sensor tracks comprising: at least two side tracks extending
parallel to a length of the substrate proximal to a first and
second side edge of the substrate respectively, the side edges
extending parallel to the longitudinal axis and between first and
second ends thereof; wetness sensing tracks extending between said
two side tracks, wherein said two side tracks each have one free
end proximal to said first end of the substrate and one connected
end being in electrical communication with said wetness sensing
tracks, and wherein the substrate is connectable to a clip-on data
processing module at a position proximal to said first end such to
form a closed electrical circuit, typically for measuring
resistance and/or capacitance therethrough. In an embodiment, the
two side tracks are feedback tracks. In an embodiment said
substrate consists of a liquid impermeable backsheet, preferably a
breathable liquid impermeable backsheet.
[0025] In a further aspect the disclosure relates to a substrate
suitable for incorporation into an absorbent article for automatic
detection of wetness events therein, the substrate comprising a
first surface capable of being arranged proximal to a body facing
side of the absorbent article and a second surface opposite said
first surface and capable of being arranged proximal to a garment
facing side of said absorbent article, said substrate comprising a
plurality of sensor tracks disposed on said first surface and said
sensor tracks comprising: at least one central track extending
parallel to a length of the substrate and parallel to a
longitudinal axis, said axis crossing a first end and a second end
of the substrate; at least two side tracks extending parallel to
the central track for only a portion thereof over said length (said
portion preferably being at a location of connection to the data
processing module) and oppositely arranged such that the central
track extends substantially therebetween, or linearly displaced
along the longitudinal axis such that the central track is
laterally spaced therefrom along said longitudinal axis; and
wetness sensing tracks extending outboard of said two side tracks
and/or central track, wherein said central track, said side tracks,
and said wetness sensing tracks are in electrical communication via
one or more shortening elements positioned proximal to said second
end and distal from said first end, and wherein the substrate is
connectable to a data processing module, that may be integral to
the substrate or a clip-on, at a position proximal to said first
end and distal from said shortening elements such to form a closed
electrical circuit, typically for measuring resistance and/or
capacitance therethrough. In an embodiment said substrate consists
of a liquid impermeable backsheet, preferably a breathable liquid
impermeable backsheet.
DESCRIPTION OF FIGURES
[0026] FIG. 1A illustrates a top view schematic of substrate
according to an embodiment of the disclosure.
[0027] FIG. 1B illustrates a top view schematic of substrate
according to an embodiment of the disclosure.
[0028] FIG. 2A illustrates a top view schematic of substrate
according to an embodiment of the disclosure.
[0029] FIG. 2B illustrates a cross-sectional schematic of the
substrate of FIG. 2A about axis A-A.
[0030] FIG. 3 illustrates a top view schematic of substrate
according to an embodiment of the disclosure.
[0031] FIG. 4A-B illustrate embodiments of portions of the sensor
tracks according to the present disclosure.
[0032] FIG. 5 is an isometric schematic view of an absorbent
article according to an aspect of the present disclosure.
[0033] FIG. 6A-C illustrate an exemplary embodiment of a clip-on
module according to the present disclosure.
[0034] FIG. 7 is a top view schematic of a substrate according to
an embodiment of the disclosure.
[0035] FIG. 8 illustrates an exemplary embodiment of a print
pattern suitable for an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0036] Unless otherwise defined, all terms used in disclosing the
invention, including technical and scientific terms, have the
meaning as commonly understood by one of ordinary skill in the art
to which this invention belongs. By means of further guidance, term
definitions are included to better appreciate the teaching of the
present invention.
[0037] As used herein, the following terms have the following
meanings:
[0038] "A", "an", and "the" as used herein refers to both singular
and plural referents unless the context clearly dictates otherwise.
By way of example, "a compartment" refers to one or more than one
compartment.
[0039] "About" as used herein referring to a measurable value such
as a parameter, an amount, a temporal duration, and the like, is
meant to encompass variations of +/-20% or less, preferably +/-10%
or less, more preferably +/-5% or less, even more preferably +/-1%
or less, and still more preferably +/-0.1% or less of and from the
specified value, in so far such variations are appropriate to
perform in the disclosed invention. However, it is to be understood
that the value to which the modifier "about" refers is itself also
specifically disclosed. "Comprise", "comprising", and "comprises"
and "comprised of" as used herein are synonymous with "include",
"including", "includes" or "contain", "containing", "contains" and
are inclusive or open-ended terms that specifies the presence of
what follows e.g. component and do not exclude or preclude the
presence of additional, non-recited components, features, element,
members, steps, known in the art or disclosed therein.
[0040] The expression "% by weight" (weight percent), here and
throughout the description unless otherwise defined, refers to the
relative weight of the respective component based on the overall
weight of the formulation or element referred to.
[0041] The recitation of numerical ranges by endpoints includes all
numbers and fractions subsumed within that range, as well as the
recited endpoints, except where otherwise explicitly stated by
disclaimer and the like.
[0042] "Absorbent article" refers to devices that absorb and
contain liquid, and more specifically, refers to devices that are
placed against or in proximity to the body of the wearer to absorb
and contain the various exudates discharged from the body.
Absorbent articles include but are not limited to diapers, adult
incontinence briefs, training pants, diaper holders and liners,
sanitary napkins and the like, as well as surgical bandages and
sponges. Absorbent articles preferably comprise a longitudinal axis
and a transversal axis perpendicular to said longitudinal axis. The
longitudinal axis is hereby conventionally chosen in the
front-to-back direction of the article when referring to the
article being worn, and the transversal axis is conventionally
chosen in the left-to-right direction of the article when referring
to the article being worn. Disposable absorbent articles can
include a liquid pervious top sheet, a back sheet joined to the top
sheet, and an absorbent core positioned and held between the top
sheet and the back sheet. The top sheet is operatively permeable to
the liquids that are intended to be held or stored by the absorbent
article, and the back sheet may or may not be substantially
impervious or otherwise operatively impermeable to the intended
liquids. The absorbent article may also include other components,
such as liquid wicking layers, liquid intake layers, liquid
distribution layers, transfer layers, barrier layers, wrapping
layers and the like, as well as combinations thereof. Disposable
absorbent articles and the components thereof can operate to
provide a body-facing surface and a garment-facing surface.
Preferably, a diaper comprises a liquid permeable "top sheet", a
liquid impermeable "back sheet", and an "absorbent medium or core"
disposed between the top sheet and the back sheet. The top sheet,
back sheet and the absorbent medium could be made from any suitable
material known to the person skilled in the art. The top sheet is
generally located at or near the bodyside surface of the article,
while the back sheet is generally located at or near the
garment-side surface of the article. Optionally, the article may
comprise one or more separate layers which are in addition to the
back sheet and are interposed between the back sheet and the
absorbent medium. Top sheet and back sheet are connected or
otherwise associated together in an operable manner.
[0043] The "absorbent medium" or "absorbent core" or "absorbent
body" is the absorbent structure disposed between the top sheet and
the back sheet of the absorbent article in at least the crotch
region of the absorbent article and is capable of absorbing and
retaining liquid body exudates. The size and the absorbent capacity
of the absorbent medium should be compatible with the size of the
intended wearer and the liquid loading imparted by the intended use
of the absorbent article. Further, the size and the absorbent
capacity of the absorbent medium can be varied to accommodate
wearers ranging from infants through adults. It may be manufactured
in a wide variety of shapes (for example, rectangular, trapezoidal,
T-shape, I-shape, hourglass shape, etc.) and from a wide variety of
materials. Examples of commonly occurring absorbent materials are
cellulosic fluff pulp, tissue layers, highly absorbent polymers (so
called superabsorbent polymer particles (SAP)), absorbent foam
materials, absorbent nonwoven materials or the like. It is common
to combine cellulosic fluff pulp with superabsorbent polymers in an
absorbent material.
[0044] "Registered" (e.g. Registered design) refers to, for
example, a print design that varies along the length of a
continuous web/film (and is repeated at intervals throughout) and
that hence requires some form of recognition on where a processing
action must happen, e.g. a cut, to ensure that consecutive discrete
products formed from the continuous web/film each have the same
print design.
[0045] "Acquisition and distribution layer", "ADL" or "surge
management portion" refers to a sub-layer which preferably is a
nonwoven wicking layer under the top sheet of an absorbent product,
which speeds up the transport and improves distribution of fluids
throughout the absorbent core. The surge management portion is
typically less hydrophilic than the retention portion, and has the
ability to quickly collect and temporarily hold liquid surges, and
to transport the liquid from its initial entrance point to other
parts of the absorbent structure, particularly the retention
portion. This configuration can help prevent the liquid from
pooling and collecting on the portion of the absorbent garment
positioned against the wearer's skin, thereby reducing the feeling
of wetness by the wearer. Preferably, the surge management portion
is positioned between the top sheet and the retention portion.
[0046] The term "adhesive" as used herein is intended to refer to
any suitable hot melt, water or solvent borne adhesive that can be
applied to a surface of a film layer in the required pattern or
network of adhesive areas to form the film-nonwoven laminate of the
present invention. Accordingly, suitable adhesives include
conventional hot melt adhesives, pressure-sensitive adhesives and
reactive adhesives (i.e., polyurethane). As used herein, the term
"adhesive bonding" means a bonding process which forms a bond by
application of an adhesive. Such application of adhesive may be by
various processes such as slot coating, spray coating and other
topical applications. Further, such adhesive may be applied within
a product component and then exposed to pressure such that contact
of a second product component with the adhesive containing product
component forms an adhesive bond between the two components.
[0047] As used herein, the term "associated or joined or adhered"
encompasses, unless expressly stated, configurations in which e.g.
a top sheet is directly joined to a back sheet by affixing the top
sheet directly to the back sheet, and also configurations wherein
the top sheet is joined to the back sheet by affixing the top sheet
to intermediate members which in turn are affixed to the back sheet
(i.e. indirectly joining). Top sheet and back sheet can be affixed
directly to each other by attachment means such as an adhesive,
sonic bonds, thermal bonds or any other attachment means known in
the art. For example, a uniform continuous layer of adhesive, a
patterned layer of adhesive, a sprayed pattern of adhesive or an
array of separate lines, swirls or spots of construction adhesive
may be used to affix top sheet to back sheet. It should be readily
appreciated that the above-described attachment means may also be
employed to interconnect and assemble together the various other
component parts of the article described herein.
[0048] The terms "back section" and "rear back section" are used
herein as synonyms and refer to the area of the absorbent article
which is contact with the back of the wearer when the absorbent
article is worn.
[0049] The term "backsheet" refers to a material forming a liquid
impermeable cover of the absorbent article. The back sheet prevents
the exudates contained in the absorbent structure from wetting
articles such as bedsheets and overgarments which contact the
disposable absorbent article. The back sheet may be a unitary layer
of material or may be a composite layer composed of multiple
components assembled side-by-side or laminated. The back sheet may
be the same or different in different parts of the absorbent
article. At least in the area of the absorbent medium the back
sheet comprises a liquid impervious material in the form of a thin
plastic film, e.g. a polyethylene or polypropylene film, a nonwoven
material coated with a liquid impervious material, a hydrophobic
nonwoven material, which resists liquid penetration, or a laminate
of a plastic film and a nonwoven material. The back sheet material
may be breathable so as to allow vapour to escape from the
absorbent material, while still preventing liquids from passing
there through. Examples of breathable back sheet materials are
porous polymeric films, nonwoven laminates of spunbond and
meltblown layers and laminates of porous polymeric films and
nonwoven materials.
[0050] The terms "belly section" and "front belly section" are used
herein as synonyms and refer to the area of the absorbent article
which is contact with the belly of the wearer when the absorbent
article is worn.
[0051] As used herein, the "body-facing" or "bodyside" surface
means that surface of the article or component which is intended to
be disposed toward or placed adjacent to the body of the wearer
during ordinary use, while the "outward", "outward-facing" or
"garment-side" surface is on the opposite side, and is intended to
be disposed to face away from the wearers body during ordinary use.
Such outward surface may be arranged to face toward or placed
adjacent to the wearers undergarments when the absorbent article is
worn.
[0052] "Bonded" refers to the joining, adhering, connecting,
attaching, or the like, of at least two elements. Two elements will
be considered to be bonded together when they are bonded directly
to one another or indirectly to one another, such as when each is
directly bonded to intermediate elements.
[0053] The term "breathable" refers to layers, preferably films or
elastic laminates, having a water vapor transmission rate (WVTR) of
at least 300 grams/m.sup.2-24 hours.
[0054] The term "consisting essentially of" does not exclude the
presence of additional materials which do not significantly affect
the desired characteristics of a given composition or product.
Exemplary materials of this sort would include, without limitation,
pigments, antioxidants, stabilizers, surfactants, waxes, flow
promoters, solvents, particulates and materials added to enhance
processability of the composition.
[0055] Further, an absorbent article can comprise "containment
flaps" or "barrier cuffs". The containment flaps are generally
thought to be particularly well suited for the containment of fecal
matter and to prevent the lateral flow of liquid waste until such
time as the liquid waste can be absorbed by the absorbent article.
Many constructions of containment flaps are known. Such containment
flaps generally comprise a proximal edge, intended to be attached
to the absorbent article, and an opposite distal edge which is
generally not attached to the absorbent article along at least a
portion of its length. An elastic member is generally located
adjacent the distal edge to assist in maintaining the containment
flap in an upright condition and in maintaining a sealing
relationship between the distal edge of the containment flap and
the body of a wearer during use. The elastic member is generally
located between two layers of material so that the elastic does not
come into contact with the body of a wearer. The containment flaps
may be manufactured from a wide variety of materials such as
polypropylene, polyester, rayon, nylon, foams, plastic films,
formed films, and elastic foams. A number of manufacturing
techniques may be used to manufacture the containment flaps. For
example, the containment flaps may be woven, non-woven, spunbonded,
carded, cast, blown or the like.
[0056] An absorbent article can comprise leg containment gaskets.
Leg "containment gaskets" help prevent leakage of bodily exudates
when the wearer exerts compressive forces on the absorbent article.
In particular, the stiffness of the leg containment gaskets
prevents twisting and bunching of the leg openings of the absorbent
article which can lead to leaks. In addition, the elasticity and
conformability of the leg containment gaskets ensures that the
bodyfacing surface of the leg containment gaskets provides an
adequate seal against the body of the wearer. The physical
properties of the leg containment gaskets, such as the thickness
and stiffness, also function to space the bodyside liner, outer
cover and absorbent core away from the wearer's body when in use.
As such, void volume is created between the wearer's body and the
bodyside liner and absorbent core of the absorbent article to help
contain body exudates.
[0057] "Mechanical bond" is an attachment between two or more
elements, components, regions, or webs and may comprise heat bonds,
pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any
other suitable non-adhesive attachment means or combinations of
these attachment means.
[0058] "Hotmelt adhesive" means a formulation that generally
comprises several components. These components typically include
one or more polymers to provide cohesive strength (e.g., aliphatic
polyolefins such as poly (ethylene-co-propylene) copolymer;
ethylene vinyl acetate copolymers; styrene-butadiene or
styrene-isoprene block copolymers; etc.); a resin or analogous
material (sometimes called a tackifier) to provide adhesive
strength (e.g., hydrocarbons distilled from petroleum distillates;
rosins and/or rosin esters; terpenes derived, for example, from
wood or citrus, etc.); perhaps waxes, plasticizers or other
materials to modify viscosity (i.e., flowability) (examples of such
materials include, but are not limited to, mineral oil, polybutene,
paraffin oils, ester oils, and the like); and/or other additives
including, but not limited to, antioxidants or other stabilizers.
For example, a typical hot-melt adhesive formulation might contain
from about 15 to about 35 weight percent cohesive strength polymer
or polymers; from about 50 to about 65 weight percent resin or
other tackifier or tackifiers; from more than zero to about 30
weight percent plasticizer or other viscosity modifier; and
optionally less than about 1 weight percent stabilizer or other
additive. It should be understood that other adhesive formulations
comprising different weight percentages of these components are
possible.
[0059] "Discontinuous bonding pattern" as used herein refers to a
pattern of bonding areas, in particular bonding areas between
layers, whereby at least in at least one region the layers are not
bonded. A discontinuous bonding pattern may comprise a connected
bonding area or multiple disconnected bonding areas. A
discontinuous bonding pattern further may comprise a connected
bonding area comprising a number of holes, where the layers are not
bonded, preferably according to a regular pattern, or it may
comprise discrete disconnected bonding areas, e.g. a point bonded
pattern which comprises a plurality of separate bonding points
surrounded by unbonded areas or a line-bonded pattern which
comprises a plurality of separate bonding lines alternated by
unbonded areas, preferably according to a regular pattern. The term
"disposable" is used herein to describe absorbent articles that
generally are not intended to be laundered or otherwise restored or
reused as an absorbent article (i.e., they are intended to be
discarded after a single use and, preferably, to be recycled,
composted or otherwise disposed of in an environmentally compatible
manner).
[0060] As used herein, the terms "elastic", "elastomeric",
"elasticity" or derivations thereof are used to describe the
ability of various materials and objects comprised of such to
reversibly undergo deformation under stress, e.g., become stretched
or extended, in at least one direction when a force is applied to
the material and to resume substantially to their original
dimensions upon relaxing, i.e., when the force is released, without
rupture or breakage. Preferably, it refers to a material or
composite which can be elongated in at least one direction by at
least 50% of its relaxed length, i.e., elongated to at least 150%
of its relaxed length, and which will recover upon release of the
applied tension at least 40% of its elongation. Accordingly, upon
release of the applied tension at 50% elongation, the material or
composite contracts to a relaxed length of not more than 130% of
its original length. Examples of suitable elastomer materials
include polyether-polyamide block copolymers, polyurethanes,
synthetic linear A-B-A and A-B block copolymers, chlorinated
rubber/EVA (ethylene-vinyl acetate) blends, EPDM
(ethylene-propylene diene monomer) rubbers, EPM (ethylene-propylene
monomer) rubbers, blends of EPDM/EPM/EVA, and the like. The term
"elasticized" or "elastified" refers to a material, layer, or
substrate that is naturally non-elastic, but which has been
rendered elastic by, for example, suitably joining an elastic
material, layer, or substrate thereto.
[0061] "Elongation" means the ratio of the extension of a material
to the length of the material prior to the extension (expressed in
percent). "Extension" means the change in length of a material due
to stretching (expressed in units of length).
[0062] As used herein the term "extensible" means elongatable in at
least one direction, but not necessarily recoverable.
[0063] The term "finished" or "final", when used with reference to
a product, means that the product has been suitably manufactured
for its intended purpose.
[0064] As used herein, the term "garment" means any type of apparel
which may be worn. This includes diapers, training pants,
incontinence products, surgical gowns, industrial workwear and
coveralls, undergarments, pants, shirts, jackets and the like.
[0065] The term "graphic" includes, but is not limited to, any type
of design, image, mark, figure, codes, words, patterns, or the
like. For a product such as a training pant, graphics will
generally include objects associated with little boys and little
girls, such as multi-color trucks, airplanes, balls, dolls, bows,
or the like.
[0066] As used herein, the term "impermeable" generally refers to
articles and/or elements that are substantially not penetrated by
aqueous fluid through the entire thickness thereof under a pressure
of 1.0 kPa or less. Preferably, the impermeable article or element
is not penetrated by aqueous fluid under pressures of 3.4 kPa or
less. More preferably, the impermeable article or element is not
penetrated by fluid under pressures of 6.8 kPa or less. An article
or element that is not impermeable is permeable.
[0067] "Integral" is used to refer to various portions of a single
unitary element rather than separate structures bonded to or placed
with or placed near one another.
[0068] "Join", "joining", "joined", or variations thereof, when
used in describing the relationship between two or more elements,
means that the elements can be connected together in any suitable
manner, such as by heat sealing, ultrasonic bonding, thermal
bonding, by adhesives, stitching, or the like. Further, the
elements can be joined directly together, or may have one or more
elements interposed between them, all of which are connected
together.
[0069] The term "laid-flat state" or "fully stretched state" or
"extended state" is intended to refer to the article when it is
flattened into a plane or is substantially flattened into a plane
and is used in contrast to when the article otherwise positioned,
such as when the article is folded or shaped in or for use by a
wearer.
[0070] The use of the term "layer" can refer, but is not limited,
to any type of substrate, such as a woven web, nonwoven web, films,
laminates, composites, elastomeric materials, or the like, or even
formulations, such as adhesives, that form a substrate upon a
change in conditions (e.g. solidification of a hotmelt adhesive
when the temperature drops below a predetermined amount). A layer
can be liquid and air permeable, permeable to air but impermeable
to liquids, impermeable both to air and liquid, or the like. When
used in the singular, it can have the dual meaning of a single
element or a plurality of elements.
[0071] The term "nonwoven fabric or web" means a sheet material
having a structure of individual fibers or threads which are
interlaid, but not in a regular manner such as occurs with knitting
or weaving processes. Nonwoven fabrics or webs have been formed
from many processes such as for example, meltblowing processes,
spunbonding processes, and bonded carded web processes.
[0072] By the terms "particle", "particles", "particulate",
"particulates" and the like, it is meant that the material is
generally in the form of discrete units. The units can comprise
granules, powders, spheres, pulverized materials or the like, as
well as combinations thereof. The particles can have any desired
shape such as, for example, cubic, rod-like, polyhedral, spherical
or semi-spherical, rounded or semi-rounded, angular, irregular,
etc. Shapes having a large greatest dimension/smallest dimension
ratio, like needles, flakes and fibers, are also contemplated for
inclusion herein. The terms "particle" or "particulate" may also
include an agglomeration comprising more than one individual
particle, particulate or the like. Additionally, a particle,
particulate or any desired agglomeration thereof may be composed of
more than one type of material.
[0073] Use of the term "substrate" includes, but is not limited to,
woven or nonwoven webs, porous films, ink permeable films, paper,
composite structures, or the like.
[0074] Superabsorbent materials (e.g. superabsorbent polymers)
suitable for use in the present disclosure are known to those
skilled in the art, and may be in any operative form, such as
particulate form, fibers and mixtures thereof. Generally stated,
the "superabsorbent material" can be a water-swellable, generally
water-insoluble, hydrogel-forming polymeric absorbent material,
which is capable of absorbing at least about 15, suitably about 30,
and possibly about 60 times or more its weight in physiological
saline (e.g. saline with 0.9 wt % NaCl). The superabsorbent
material may be biodegradable or bipolar. The hydrogel-forming
polymeric absorbent material may be formed from organic
hydrogel-forming polymeric material, which may include natural
material such as agar, pectin, and guar gum; modified natural
materials such as carboxymethyl cellulose, carboxyethyl cellulose,
and hydroxypropyl cellulose; and synthetic hydrogel-forming
polymers. Synthetic hydrogel-forming polymers include, for example,
alkali metal salts of polyacrylic acid, polyacrylamides, polyvinyl
alcohol, ethylene maleic anhydride copolymers, polyvinyl ethers,
polyvinyl morpholinone, polymers and copolymers of vinyl sulfonic
acid, polyacrylates, polyacrylamides, polyvinyl pyridine, and the
like. Other suitable hydrogel-forming polymers include hydrolyzed
acrylonitrile grafted starch, acrylic acid grafted starch, and
isobutylene maleic anhydride copolymers and mixtures thereof. The
hydrogel-forming polymers may be lightly crosslinked to render the
material substantially water insoluble. Crosslinking may, for
example, be by irradiation or covalent, ionic, Van der Waals, or
hydrogen bonding. The superabsorbent material may suitably be
included in an appointed storage or retention portion of the
absorbent system, and may optionally be employed in other
components or portions of the absorbent article. The superabsorbent
material may be included in the absorbent layer or other fluid
storage layer of the absorbent article of the present invention in
an amount up to about 60% by weight. Typically, the superabsorbent
material, when present, will be included in an amount of about 10%
to about 100% by weight, based on the total weight of the absorbent
layer.
[0075] "Superabsorbent polymer particles" or "SAPs" refer to
water-swellable, water-insoluble organic or inorganic materials
capable, under the most favorable conditions, of absorbing at least
about 10 times their weight, or at least about 15 times their
weight, or at least about 25 times their weight in an aqueous
solution containing 0.9 weight percent sodium chloride. In
absorbent articles, such as diapers, incontinent diapers, etc., the
particle size is typically ranging between 100 to 800 .mu.m,
preferably between 300 to 600 .mu.m, more preferably between 400 to
500 .mu.m.
[0076] The term "topsheet" refers to a liquid permeable material
sheet forming the inner cover of the absorbent article and which in
use is placed in direct contact with the skin of the wearer. The
top sheet is typically employed to help isolate the wearer's skin
from liquids held in the absorbent structure. The top sheet can
comprise a nonwoven material, e.g. spunbond, meltblown, carded,
hydroentangled, wetlaid etc. Suitable nonwoven materials can be
composed of man-made fibres, such as polyester, polyethylene,
polypropylene, viscose, rayon etc. or natural fibers, such as wood
pulp or cotton fibres, or from a mixture of natural and man-made
fibres. The top sheet material may further be composed of two
fibres, which may be bonded to each other in a bonding pattern.
Further examples of top sheet materials are porous foams, apertured
plastic films, laminates of nonwoven materials and apertured
plastic films etc. The materials suited as top sheet materials
should be soft and non-irritating to the skin and be readily
penetrated by body fluid, e.g. urine or menstrual fluid. The inner
coversheet may further be different in different parts of the
absorbent article. The top sheet fabrics may be composed of a
substantially hydrophobic material, and the hydrophobic material
may optionally be treated with a surfactant or otherwise processed
to impart a desired level of wettability and hydrophilicity.
[0077] As used herein, the term "transverse" or "lateral" refers to
a line, axis, or direction which lies within the plane of the
absorbent article and is generally perpendicular to the
longitudinal direction.
[0078] "Ultrasonic welding" refers to a technology which joins two
materials by melting them with heat generated from ultrasonic
oscillation and then laminating them together, such that the molten
materials flow and fill the gap between the two unaffected portions
of the two materials, respectively. Upon cooling and shaping, the
two materials are joined together.
[0079] "Form-driven locking" refers to locking via the shape of an
element, such as a key lock wherein the shape of an element
provides a resisting force to the opening thereof.
[0080] "Force-driven locking" refers to locking via a means
selected from the group consisting of electromechanical, magnetic,
adhesive and combinations thereof.
[0081] "Substantial portion" as used herein with reference to a
element/component (e.g. wetness sensing tracks), refers to at least
80%, preferably at least 90%, more preferably at least 95%, of said
element/component, generally measured as a surface area taken in
the laid flat state of the absorbent article.
[0082] "Substantially perpendicular (or parallel)" refers to an
element extending at an angle of not more than 35.degree.,
preferably less than 25.degree., more preferably less than
20.degree., even more preferably less than 15.degree., even more
preferably less than 10.degree., most preferably less than
5.degree., from the referred perpendicular (or parallel) axis.
[0083] Embodiments according to the disclosure will now be
described. It is understood that technical features described in
one or more embodiments maybe combined with one or more other
embodiments without departing from the intention of the disclosure
and without generalization therefrom.
The Substrate
[0084] In an embodiment, a substrate 1 suitable for incorporation
into an absorbent article 100 for automatic detection of wetness
events therein and/or risk of exudate leakage therefrom, comprises:
a first surface 2 capable of being arranged proximal to a body
facing side of the absorbent article 100 and a second surface 3
opposite said first surface 2 and capable of being arranged
proximal to a garment facing side of said absorbent article 100,
said substrate 1 comprising a plurality of sensor tracks 101
disposed on said first surface 2 and said sensor tracks 101
comprising at least one feedback track 4 (herein also referred to
as central track although the term "central" is not intended to be
limiting unless expressly stated e.g. such track may be skewed with
respect to the centerline of the substrate and does not necessarily
have to extend along the center thereof) extending substantially
parallel to a length L of the substrate; and one or more exudate
sensing tracks 9 (herein also referred to as wetness sensing
tracks) in electrical communication with said feedback track 4,
wherein said feedback track 4 and exudate sensing tracks 9 are
connected in series and wherein the substrate 1 is connectable to a
clip-on data processing module 103 at a position proximal to a
first end 5 of the substrate 1 such to form a closed electrical
circuit, typically for measuring resistance, impedance and/or
capacitance therethrough. Advantageously this arrangement allows
for efficient exudate detection whilst being cheap and fast to
make, both being desirable in disposable products. Moreover, it has
been found that connection in series allows for efficacious exudate
detection whilst it being simple to apply onto a substrate into a
scalable production process.
[0085] Preferably, the exudate sensing tracks 9 cover a greater
surface area of the substrate 1 than the feedback track 4, and
wherein said exudate sensing tracks 9 extend both in a direction
substantially parallel to the length L and a direction
substantially perpendicular thereto. Advantageously this allows for
maximized exudate detection. Preferably, the exudate sensing tracks
9 are in the form of a grid structure, typically as will be
described in more detail hereinbelow.
[0086] In an embodiment, as shown in exemplary FIG. 1 to 4, the
substrate 1, suitable for incorporation into an absorbent article
100 for automatic detection of wetness (and/or exudate) events
therein, comprises a first surface 2 capable of being arranged
proximal to a body facing side of the absorbent article 100 and a
second surface 3 opposite said first surface 2 and capable of being
arranged proximal to a garment facing side of said absorbent
article 100, said substrate 1 comprising a plurality of sensor
tracks 101 disposed on said first surface 2 and said sensor tracks
101 comprising: at least one central track 4 extending parallel to
a length L of the substrate and parallel to a longitudinal axis y-y
crossing a first end 5 and a second end 6 of the substrate 1; at
least two side tracks 7,8 extending parallel to the central track 4
(by "parallel" herein it is intended substantially parallel and not
necessarily limited to the side tracks extending the entire length
L, although preferred) and oppositely arranged such that the
central track 4 extends therebetween; and wetness sensing tracks 9
extending outboard of said two side tracks 7,8, wherein said
central track 4, said side tracks 7,8, and said wetness sensing
tracks 9 are in electrical communication via one or more shortening
elements 10 positioned proximal to said second end 6 and distal
from said first end 5, and wherein the substrate 1 is connectable
to a clip-on data processing module 103 at a position proximal to
said first end 5 and distal from said shortening elements 10 such
to form a closed electrical circuit, typically for measuring
resistance and/or capacitance therethrough. It has been
advantageously found that a substrate that comprises the above
described sensor track arrangement provides for accurate detection
of exudates as well as being particularly suitable for fully
scalable in-line mass production at high speeds, without the need
to change arrangement depending on product sizes. For example, an
advantage of positioning the wetness sensing tracks outboard of the
other tracks is that if/when the substrate is cut to form for
example leg openings (which may vary depending on product size),
the circuitry is not damaged (since e.g. the central feedback track
would always remain intact) and wetness detection is still ensured
across the areas of greater risk of leakage that are located
proximal to the edges and/or sides of the absorbent article.
[0087] Preferably, the central track(s) 4 has the highest
conductivity compared to other sensor tracks 101.
[0088] In any of the embodiments herein, the central track(s) 4 may
extend proximal to a centerline of the substrate 1 extending
parallel to the length L thereof.
[0089] In an embodiment, the distance between the at least two side
tracks 7,8 is less than 0.3W, wherein W is the width of the
substrate 1 extending perpendicular to the length L thereof.
Preferably, said distance is less than 0.2W, more preferably said
distance is from 0.01W to 0.18W, even more preferably from 0.04W to
0.15W. Advantageously, limiting the distance between said tracks
allows for a larger wetness sensing surface area for wetness event
detection and may further make any subsequent insulation of the
feedback track easier to achieve in fast inline production as will
be further explained in the following embodiments.
[0090] In an embodiment, the distance between each side track 7,8
and lateral side edges 12,13 of the substrate 1 is greater than
0.2W, preferably greater than 0.25W, even more preferably from
greater than 0.26W to less than 0.5W, even more preferably from
0.27W to 0.47W, most preferably from 0.3W to 0.4W. Similarly to the
above, it is not only desirable that the side tracks are spaced
close to each other but further that the distance between each side
track and the lateral edges of the substrate is as high as possible
in order to increase the sensing area covered by the wetness
sensing tracks 9.
[0091] In an embodiment, the central track 4 extends along a
centerline of the substrate 1 running along the longitudinal axis
y-y. Preferably wherein each side track 7,8 is symmetrically
disposed on either side of said central track 4. An advantage of
this arrangement is that shorting distances are reduced hence
limiting the risk of circuit failure and/or signal noise.
[0092] In a preferred embodiment, the substrate 1 consists of a
liquid impermeable backsheet, preferably a breathable liquid
impermeable backsheet.
[0093] In an embodiment, the wetness sensing tracks 9 are
characterized by resistance (or more generally speaking impedance)
values. Indeed, resistive measurements described herein are not
limited to direct current (DC) power sources but also and most
preferably alternating current (AC) power sources. Said wetness
sensing tracks 9 generally having an adjusted resistance/impedance
design, that can further be defined by a mathematical distribution
model in the variation of respective resistance/impedance values
over a surface of the absorbent article, said distribution model
may be a linear, quadratic or logarithmic, preferably logarithmic,
distribution.
[0094] In a preferred embodiment, the resistance/impedance of the
wetness sensing tracks 9 proximal to the lateral side edges 12,13
and/or first/second ends 5,6 of the substrate 1 is greater than on
any other portion of said substrate 1 (typically said other
portions being inboard of said lateral side edges 12,13 and/or
first/second ends 5,6 and proximal to the middle and/or center of
the substrate 1). In an alternative embodiment said
resistance/impedance is substantially the same throughout the
wetness sensing tracks 9.
[0095] Especially, but not only, in the latter embodiment (i.e.
also independently therefrom) the wetness sensing tracks 9 may form
a grid pattern across the substrate 1 wherein said grid comprises
resistive (and/or conductive) elements running both substantially
parallel to the longitudinal axis y-y as well as substantially
perpendicular thereto. The latter arrangement is beneficial for
ensuring reliable sensing of wetness events also upon saturation of
the product which inevitably results in expansion of the absorbent
core of the absorbent article and thus more prone to delamination
of the absorbent core components (e.g. the core wrap) from the
backsheet. Surprisingly such a grid structure has been found to be
beneficial in providing continued and reliable detection also in
such extreme conditions.
[0096] In a preferred embodiment, the grid pattern may vary across
the surface of the substrate 1, and arranged such that the distance
between each resistive (and/or conductive) elements (also referred
to herein as members) is lower at positions proximal to the lateral
edges 12,13 and the sides 5,6 of the substrate 1 as compared to
other regions of the substrate 1 typically proximal to the center
thereof. An advantage is to permit accurate risk of leakage
detection which has been found most necessary at proximity to the
edges of the product.
[0097] In an embodiment, the resistance/impedance of the wetness
sensing tracks 9 varies cross the surface of the substrate 1,
preferably such that it is higher in regions proximal to the
lateral side edges 12,13 of the substrate 1. The
resistance/impedance may be increased by limiting the amount of
electrically conducting/conductive material, for example in the
instance of printed sensor tracks, the tracks may be made thinner
and/or the total % wt of printed sensor tracks proximal to said
lateral side edges may be lower than the total % wt of printed
sensor tracks distal from said lateral side edges 12,13 and
proximal to a center of the substrate 1.
[0098] Preferably, the sensor tracks 101 comprise an electrically
conductive material, and are preferably printed sensor tracks. In a
preferred embodiment, the printed sensor tracks 101 comprise,
preferably consist of, a carbon-based ink and/or a conductive
polymer-based ink, preferably the carbon-based ink comprising a
conductive compound selected from the group consisting of graphene,
graphite, nano-carbon-tubes and mixtures thereof, preferably the
conductive polymer-based ink comprising a conductive compound
selected from the group consisting of polyacetylene, polypyrrole,
polyaniline and copolymers thereof, more preferably selected from
the group consisting of poly(pyrrole)s (PPY), polyanilines (PANI),
poly(thiophene)s (PT), poly(p-phenylene sulfide) (PPS),
poly(p-phenylene) (PPP), Poly(acetylene)s (PAC), Poly(p-phenylene
vinylene) (PPV), poly(3,4-ethylenedioxythiophene) (PEDOT), and
mixtures thereof, most preferred conductive polymer-based ink
comprising poly(3,4-ethylenedioxythiophene) polystyrene sulfonate
(PEDOT:PSS). An advantage of this arrangement is that fast
production is achieved whilst ensuring good compatibility with the
end/final product unlike with the addition of foreign conductive
elements like copper wires and the like, which are more prone to
tearing the liquid impermeable substrate. Indeed, it is preferred
in the disclosure herein to avoid metal containing inks (i.e. ink
is free of metals) particularly due to the environmental impact to
disposability.
[0099] In a highly preferred embodiment, the substrate 1 further
comprising an insulating layer 200, preferably being liquid
impermeable, adhered thereto and sized to cover the at least one
central track 4 and at least a portion of the side tracks 7,8
(typically said "at least portion" being proximal to a position
where the clip-on data processing module is connected to said
substrate), said insulating layer 200 adapted to provide a seal
and/or barrier to liquid from coming into contact with said central
track 4 and said at least portion of side tracks 7,8, preferably
wherein the wetness sensing tracks 9 remain exposed and are not
covered by said insulating layer 200. An advantage of this
arrangement is that the insulating layer protects the central
tracks and portions of the side tracks from coming into direct
contact with exudates and thus limiting the risk of false
positives, noise and even failure of detection. This not only along
the length L for the central track but importantly also the side
tracks for portions proximal to the connection position of the
clip-on unit
[0100] In an embodiment, the insulating layer 200 is a
nonconductive substrate such as a film typically comprising
polyethylene, alternatively the insulating layer 200 is in the form
of a non-conductive adhesive (preferably a hotmelt adhesive) and/or
non-conductive ink.
[0101] In an embodiment, the insulating layer 200 has a length
extending parallel to the length L of the substrate 1 that is equal
or less than said length L of the substrate 1. Preferably the
length of said insulating layer 200 is from 0.8L to L, preferably
from 0.85L to 0.99L.
[0102] In a highly preferred embodiment the width w of the
insulating layer 200 is less than the width W of the backsheet
(and/or substrate 1), preferably is less than 0.5W, more preferably
from 0.05W to 0.35W, even more preferably from 0.08W to 0.30W, most
preferably from 0.1W to 0.2W.
[0103] In a preferred embodiment, the insulating layer 200 has a
thickness (typically extending along an axis perpendicular to both
the length and width w of said insulating layer) of 0.7 mm or less,
preferably from 0.010 mm to 0.500 mm, more preferably from 0.015 mm
to 0.200 mm, more preferably from 0.02 mm to 0.08 mm. Thickness
measurements may be made according to ASTM D1777 and typically
using a thickness tester such as C640, or CHY-C2A of Labthink
International, 200 River's Edge Drive, Medford, Mass., USA.
[0104] Preferably, the insulating layer 200 comprises the one or
more shortening elements 10, such that the central track 4, the
side tracks 7,8, and the wetness sensing tracks 9 are in electrical
communication via said shortening elements 10 when said insulating
layer 200 is joined to the substrate 1. An advantage of this
arrangement is that it allows a non-registered process to be used
in processing the substrate, indeed registered printing of
backsheets would add complexity and cost to the overall
production.
[0105] In an embodiment, the substrate 1 comprises at least two,
preferably at least three, central tracks 4 extending parallel to
each other, and further being in electrical communication with each
other via one or more secondary shortening elements 11, preferably
said secondary shortening elements 11 being located distal from the
shortening elements 10 and between said shortening elements 10 and
the first end 5 of the substrate 1 typically such to provide one or
more resistance identifiers, most preferably wherein the insulating
layer 200 comprises said secondary shortening elements 11. An
advantage is that identifiers such as the level of absorbency of
the absorbent article, the size etc. can be pre-defined and
detected when connected to the clip-on module, based on the
location of the secondary shorts generating a pre-set resistance
level that the module can detect by comparing for example the
initial resistive measurement upon connection to the absorbent
article versus preset values that may be stored in a memory within
the unit.
[0106] In an alternative embodiment, as shown in FIGS. 7 and 8,
when the sensor design is generally registered, the shortening
elements 10 and/or secondary shortening elements described herein
are directly comprised on the substrate 1 and not on the insulating
layer 200. In such embodiments the wetness sensing tracks 9 may
comprise more than one densified areas wherein said densified areas
are formed by a higher concentration of said sensing tracks 9
compared to other areas of said sensing tracks 9 (e.g. reduced
pitch between elements of the sensing tracks 9 versus the pitch
between elements of said sensing tracks 9 in the other areas, or a
higher surface area coverage of said sensing tracks 9 versus the
surface area coverage in the other areas). Preferably, said
densified areas are located at a position proximal to the lateral
side edges 12,13 at a central portion of the crotch region and/or
at positions proximal to the contour of an absorbent core when
laminated over the substrate to form the assembled absorbent
article. As shown in FIG. 8, the sensor design my comprise
registration marks 300 arranged to provide a trigger to a
registering device to carry out process steps, such as cutting, at
a precise position during the manufacturing process and assembly of
the substrate to other components for assembling the final
absorbent article.
[0107] When the substrate 1 comprises two or more central tracks 4,
the longitudinal axis y-y may extend in between at least two of
said two or more central tracks 4. An advantage of this arrangement
is that it enables reliable location of the clip on module for
correct and appropriate electrical connection to the respective
tracks.
[0108] In an embodiment, at least a substantial portion of the
wetness sensing tracks 9 remains exposed to liquids and are not
covered by the insulating layer 200. Preferably at least 90%, more
preferably at least 95%, even more preferably at least 98%, most
preferably 100%, of the surface area of the wetness sensing tracks
remains exposed.
[0109] In an embodiment, the wetness sensing tracks 9 are in the
form of a repeating grid and/or pattern along the length L of the
substrate 1 and a dimension substantially perpendicular thereto,
said grid and/or pattern preferably comprising a plurality of at
least partially interconnected resistive members 301, 302, 303,
304, 305, 306 each having a shape selected from straight lines;
curved lines; wave-like; geometrically shaped such as squares,
parallelepipeds, parallelogram, triangles, circles, ellipses, dots,
and combinations thereof; decorative elements such as flowers,
butterflies, and combinations thereof; and combinations thereof.
Preferably, the wetness sensing tracks 9 form of a repeating grid
or pattern along the length L of the substrate 1 and a dimension
perpendicular thereto, said grid and/or pattern preferably
comprising a plurality of at least partially interconnected
resistive members each having a shape selected from straight lines
and/or curved lines, where lines can be replaced by interconnected
decorative elements that form a pattern along the track. The width
of said lines and/or the connected pattern that is replacing the
lines may be of up to 50% of the distance between neighboring
tracks. The tracks in longitudinal direction may be arranged in
parallel to the side tracks 7,8 or at an angle to it of up to
45.degree., preferably from 2.degree. to 30.degree., more
preferably from 5.degree. to 25.degree.. Other tracks can be
arranged perpendicular to the side tracks 7,8 or on an angle to it
of up to +/-45.degree. preferably from 2.degree. to 30.degree.,
more preferably from 5.degree. to 25.degree. (the angles measure
either as a positive or negative angle e.g. +45.degree. or
-45.degree.).
[0110] In a preferred embodiment, a plurality of the resistive
members, preferably a majority, more preferably all, extending in a
direction towards the lateral side edges 12,13 of the substrate 1
are at an angle .alpha. to the longitudinal axis y-y, said angle
.alpha. being from 2.degree. to 45.degree., preferably from
5.degree. to 30.degree., more preferably from 8.degree. to
25.degree., even more preferably from 10.degree. to 20.degree.. An
advantage of this arrangement is that during the application step
in the process, a reduction of the wear and tear of the components
is achieved compared to when the members extend at angles of
greater than 45.degree. (especially right angles). This arrangement
has been found beneficial to still provide accurate sensing also at
saturation conditions (which may lead to delamination issues as
described above) hence making it a highly optimal arrangement from
both a functionality as well as production point of view.
[0111] Preferably, a plurality of the resistive members wetness
sensing tracks 9, preferably a majority, more preferably all,
extending in a direction towards the first and/or second ends 5,6
of the substrate 1 are at an angle .beta. to the longitudinal axis
y-y, said angle .beta. being from 2.degree. to 45.degree.,
preferably from 5.degree. to 30.degree., more preferably from
8.degree. to 25.degree., even more preferably from 10.degree. to
20.degree.. An advantage of this arrangements is that the benefits
described above are further exacerbated.
[0112] In an embodiment as shown in exemplary FIG. 3, at least one,
preferably each, of the side tracks 7,8 is discontinuous along an
axis parallel to the length L of the substrate 1 such to force a
current through the wetness sensing tracks 9 towards regions
proximal to lateral edges 12,13 of the substrate 1 said lateral
edges 12,13 extending between the first and second ends 5,6 and
along the length L of the substrate 1, preferably wherein at least
a portion of the wetness sensing tracks 9 are further alternatingly
directly connected and disconnected to the respective side tracks
7,8 along the length L of the substrate 1. Preferably said portion
of the wetness sensing tracks 9 is proximal to the first and/or
second ends 5,6 of the substrate 1. An advantage of this
arrangement is that better accuracy of exudate detection is
achieved where it is needed most for assessing risk of leakage i.e.
proximal to the sides and/or ends of the substrate. Moreover, by
having an alternating connection of the wetness sensing tracks as
shown in FIG. 3 in regions proximal to the first and/or second
ends, improved detection capability is enhanced also proximal to
the central portion of the substrate in regions where further
potential leakage and/or discomfort may occur. Such arrangement has
surprisingly been found beneficial when using a random
non-registered print design.
[0113] In an embodiment, the wetness sending tracks 9 are
non-evenly distributed across the surface of the substrate 1 and
arranged such that portions of said wetness sensing tracks proximal
to the lateral edges 12,13 of the substrate 1 are thinner than
those portions distal therefrom and proximal to the center of the
substrate. Preferably, tracks running perpendicular to the
longitudinal axis y-y are thinner than those running parallel
thereto.
[0114] In any of the embodiments herein, the substrate 1 further
comprises temperature sensing tracks outboard of the wetness
sensing tracks. An advantage of this embodiment is that by further
monitoring temperature at the extremities of the substrate a more
accurate detection of leakage may be gathered in addition to the
resistance/capacitance measurements.
The Absorbent Article
[0115] Articles (and substrates) herein are preferably of the
disposable kind.
[0116] In an embodiment, the absorbent article 100 according to the
present disclosure (as exemplified in FIG. 5) is typically a
disposable diaper or pant, and suitable for detecting a wetness
(i.e. urine and/or feces) event therein and/or risk of exudate
leakage therefrom, said absorbent article comprising: a liquid
impermeable backsheet; a liquid permeable topsheet; and an
absorbent core interposed between said backsheet and topsheet,
wherein said backsheet comprises the substrate 1 described herein,
typically the backsheet, absorbent core and topsheet forming a
chassis of the absorbent article.
[0117] In an embodiment, the absorbent article 100 is arranged to
measure and monitor the amount of exudates across a surface covered
by the wetness sensing tracks 9, combined with detection of the
position of the subject (e.g. sitting, lying on back or side etc.)
by the motion sensor comprised in the module 103 described herein
above. The position information my then be used by the processor to
calculate an effect of said position (e.g. angled gravity effects)
on the speed of saturation at a given area of the absorbent article
and is compared and/or combined with sensed wetness signals
received in said given area by the respective portion of the
wetness sensing tracks 9. Preferably, the saturation level is
determined for a plurality of individual and/or local areas within
the absorbent article. This is advantageous over prior art systems
that rather provide total saturation information, in that leakage
risk may actually be high in a specific single region of the
absorbent article even if the overall/total saturation of the
absorbent article is far from being reached. In such instances,
leakage may still occur and a warning to the care giver not
provided, to the contrary the absorbent articles described herein
advantageously monitor area-specific wetness information combined
with position data in order to more effectively warn care givers
when the risk of leakage is high such to prompt an intervention
(e.g. rotate the patient to a new position or replace the absorbent
article).
[0118] Since not only the volume inside an absorbent article
defines the moment of leakage, but the position of a person's body
over time also plays a fundamental role in determining the
distribution of the liquid inside the absorbent article. The
present disclosure addresses this with the combination of totally
absorbed volume and more accurate position detection of a person's
body (e.g. lying (on the belly/back/left side/right side), sitting
or standing) over time determines when an absorbent article will
most likely start leaking. The more accurate position detection as
referred to, is for instance not only related to lying or sitting,
but implying that a person is lying on a particular side of its
body, or in case of sitting, that a person is sitting straight or
under a certain angle. It has surprisingly been found that the
particular sensor track arrangement described herein
synergistically operates with the position sensing system to
provide accurate determination of risk of leakage in use.
[0119] The absorbent article may further comprise additional
components that are common in the art and selected from the group
consisting of: a liquid distribution layer (ADL) positioned between
the topsheet and the absorbent core; elastic or non-elastic back
ears joined to the chassis at a position proximal to the second end
6 of the substrate 1 forming the backsheet; super absorbent polymer
particles and/or fibers typically comprised within the absorbent
core; cellulose fibers typically comprised within the absorbent
core; fastening tapes joined to the back ears for adhesive and/or
mechanical coupling with a garment facing surface of the backsheet
at a position proximal to the first end 5; elastic waistband
positioned proximal to the first and/or second ends 5,6; and
combinations thereof. When the absorbent article is a pant, the
absorbent article may comprise a front belt positioned proximal to
the first end 5 and a rear belt positioned proximal to the second
end 6, said belts being separated from each other by the chassis of
the absorbent article and being directly joined to each other via
two opposite side seams, said belts typically being elastic.
[0120] In an embodiment, the absorbent core comprises a nonwoven
core wrap typically arranged such that there is no folding (i.e. no
nonwoven overlap) of said core wrap coming in direct contact with
the backsheet comprising the sensor tracks.
[0121] In an embodiment, the absorbent article comprises a
removable clip-on data processing module 103 adapted to monitor and
process resistance and/or capacitance data acquired from the
wetness sensing tracks 9, said clip-on data processing module 103
being connectable to the at least one central track 4 and the at
least two side tracks 7,8 via a slit 15 and/or pocket on the
backsheet enabling an electrically conductive portion of said
module 103 to directly come in electrical communication with said
at least one central track 4 and said at least two side tracks 7,8,
preferably the slit and/or pocket arranged to accommodate at least
50%, preferably at least 60%, more preferably at least 70%, even
more preferably at least 80%, of the total surface area of the
clip-on data processing module 103 therein. An advantage of this
arrangement is that the module remains nicely secured to the
absorbent article as well as being protected from accidental
disengagement during movements of the subject/wearer.
[0122] Preferably, the substrate 1 is positioned such that the
first surface 2 faces the absorbent core, and preferably wherein
the insulating layer 200 is joined to said substrate 1 such that a
liquid impermeable seal is formed providing a barrier to exudates
expelled by a subject, when wearing the absorbent article, from
coming into direct contact with the at least one central track 4
and at least a portion of the at least two side tracks 7,8.
Preferably, said insulating layer 200 is adapted to prevent liquid
from coming into contact with said central track 4 and at least a
portion of said side tracks 7,8. It is highly preferred that at
least a substantial portion of the wetness sensing tracks 9 remains
exposed and not covered by said insulating layer 200.
[0123] In an embodiment, the insulating layer 200 comprises the one
or more shortening elements 10, such that the central track 4, the
side tracks 7,8, and the wetness sensing tracks 9 are in electrical
communication via said shortening elements 10 only when said
insulating layer 200 is joined to the substrate 1. An advantage of
this arrangement is that a greater degree of flexibility is
provided as well as simplifying the process of assembly for reasons
that will be better explained in the process section herein and
thus allowing for an effective non-registered process to be
used.
[0124] In an embodiment, the insulating layer 200 adheres to the
backsheet via a non-electrically-conductive adhesive and/or
mechanical bonding, wherein the mechanical bonding is preferably
selected from ultrasonic bonding, thermal bonding, and combinations
thereof. An advantage of this arrangement is that noise and/or risk
of compromising the wetness detection data is minimized.
[0125] In a preferred embodiment, the adhesive and/or mechanical
bonding is comprised across a length and width of the insulating
layer 200 in an effective amount such that bonding is achieved with
the backsheet and a liquid impermeable seal is formed over the at
least one central track 4 and the at least portions of the two side
tracks 7,8, preferably wherein at a location proximal to the first
end 5 of the substrate where the clip-on data processing module 103
is to be connected the adhesive is present only outboard of the at
least two side tracks 7,8 and not therebetween such to form a
pocket for receiving one or more electrically conducting connection
ports 33 of the module 103.
[0126] In a preferred embodiment, the first end 5 of the substrate
(and/or backsheet) corresponds to the front (or belly portion) of
the absorbent article and the second end 6 corresponds to the back
of the absorbent article.
[0127] As shown in FIG. 3 the at least a portion of the wetness
sensing tracks 9 that may be alternatingly directly connected and
disconnected to the respective side tracks 7,8 along the length L
of the substrate 1 is preferably located at positions proximal to
the front and/or back (and typically not a central portion
positioned therebetween) of the absorbent article. An advantage is
that improved wetness monitoring is achieved in the front and back
regions of the absorbent article that, together with the sides
thereof, is found to be most desirable when detecting risk of
leakage.
[0128] In an embodiment, the backsheet comprises a slit 15 at a
location proximal to the first end 5 of the substrate where the
clip-on data processing module 103 is to be connected, said slit
being sized such to receive therethrough, typically only, the
flexible connection member 31 (typically comprising the connection
ports 33) of the clip-on data processing module 103 and wherein,
once said clip-on data processing module 103 is connected, said
backsheet is interposed between the free end 32 of the flexible
connection member 31 and the housing 30 of the clip-on data
processing module 103 such that said free end 32 does not come in
direct contact with said housing at a position proximal to said
free end 32, preferably wherein the housing 30 is positioned on a
garment facing side of the backsheet and the free end 32 of the
flexible connection member 31 on a body facing side of the
backsheet. An advantage of this arrangement is that a secure
connection may be achieved between the module and the chassis of
the article and in particular a very secure electrical connection
to the sensor tracks is enabled, whilst it being protected from
soiling by internal and/or external elements like dust, exudates,
food and the like.
The Clip-on Processing Module
[0129] Clip-on processing modules for use herein are generally of
the re-fastenable and replaceable kind. What is meant by this is
that the modules are adapted to be joined to the absorbent article
and subsequently decoupled therefrom once the absorbent article is
to be disposed. Thus, the modules are adapted for multiple use and
may be connected to a plurality of absorbent articles in sequence
(i.e. one after the other) and to the same or different
patient/subject. The modules may be cleaned and battery charged in
between a plurality of absorbent article changes. The net result is
that an efficient, cost-effective and environment-compliant
solution is provided.
[0130] In an aspect, the disclosure comprises a clip-on data
processing module 103 suitable for removable attachment to a
chassis of an absorbent article 100 for automatic detection of
wetness events therein and more preferably the risk of exudate
leakage, the module 103 comprising: a housing 30; and a flexible
connection member 31 coupled to said housing 30 and having a free
end 32 being cantilevered from said housing 30, said end 32
comprising one or more electrically conducting connection ports 33,
wherein the housing 30 comprises therein a data processing system,
said data processing system comprising a power source, a processor,
and a transmitter; and a motion sensor in electrical communication
with at least said processor, the flexible connection member 31
being arranged to fasten to a surface of the absorbent article 100,
wherein the absorbent article 100 comprises a plurality of sensor
tracks 101, and to electrically connect at least two of said
plurality of sensor tracks to said processing system via said one
or more electrically conducting connection ports 33.
[0131] In an embodiment, the motion sensor (herein also referred to
as position sensor) comprises an accelerometer or gyroscope.
Preferably, wetness event data and the position data as measured by
the module 103 are combined for determination of the saturation
level at a specific location of the absorbent article, typically
determined respectively for a plurality of local areas of said
absorbent article. An advantage of this arrangement is that it more
accurately provides warnings to the care givers when the risk of
leakage is high thus allowing them to intervene and limit
additional cleaning time and costs. As opposed to state of the art
systems, the motion sensor described herein is not particularly
used to optimize the volume measurement, but rather to combine the
position data with the resistive/impedance measured data in order
to determine a "local" saturation of the absorbent article, and
thereafter preferably predict the risk of leakage in said localized
area of the absorbent article.
[0132] In an embodiment, the transmitter may be arranged to
transmit/forward the data measured to a server or end-user, more
preferably said data is transmitted to a server (for example a
cloud-based server) wherein further processing of the data
(although the processing may also be carried out at least in part
also within the processing unit of the clip-on module in the
disclosure herein) via for example a mathematical logarithmic model
is carried out for determination of patient related information,
including risk of leakage within the absorbent article, and the
further processed information is then uploaded on a graphical user
interface to simply communicate to the care giver a patient status,
including providing a warning when the absorbent article is close
to a point of leakage (e.g. above a predefined probability
threshold such as above 80%, preferably above 85%, more preferably
from 88% to 99%). Further embodiments are described in the
incontinence management section hereinunder.
[0133] In an embodiment, the power source comprised in the housing
comprises a battery. The battery and the housing 30 can be
disconnected from each other and from the module 103. Whenever the
battery has to be replaced e.g. because it has a remaining charging
capacity of only about 10% or less left, typically a waring is
provided on a user interface to allow a care giver to intervene and
replace the battery by simply removing it from the housing 30 and
replacing it with another (e.g. fully charged) one, while the
measuring electronics (e.g. processor, motion sensor, sensor
tracks, and the like) can continue performance under power via a
micro-charger that is provided and connected thereto during the
battery replacement. Time and money is saved whereas the entire
module 103 doesn't have to be removed/replaced when only the low or
flat battery has to be replaced. Alternatively, the battery may be
an integral (non-disconnectable) portion of the unit within the
housing.
[0134] In an embodiment, the flexible connection member 31
comprises an elastomer, and wherein the one or more electrically
conducting connection ports 33 are exposed from said elastomer when
the clip-on data processing module 103 is not connected to the
chassis of the absorbent article 100. Preferably, the elastomer
comprises one or more polymers having a monomer selected from the
group consisting of carbon, silicone and mixtures thereof,
preferably wherein the elastomer is selected to slide when
contacted to PE. Advantages of this arrangement include improved
comfort achieved upon connection as well as ease of cleaning after
use.
[0135] In an embodiment, the housing 30 is covered by an elastomer
which can be the same and/or different from that comprised in the
flexible connection member 31 and may be of a monolithic structure
or different component therefrom. When the clip-on data processing
module 103 comprises a display, only the display may be exposed
from said elastomer cover. An advantage of this arrangement is
improved sealing of components within the housing particularly from
liquids such as exudates and/or food.
[0136] In an embodiment, the housing 30 and the free end 32 of the
flexible connection member 31 comprise a locking member 34 to
secure the clip-on data processing module 103 to the absorbent
article 100, preferably said locking member consisting of a
form-driven locking member or a force-driven locking member and
typically arranged to fasten the free end 32 to a position proximal
to a portion of the housing 30. Preferably, the locking member
comprises a magnet arranged to provide a securing force between the
free end 32 and the housing 30 such that said free end 32 adheres
directly or indirectly, preferably indirectly via the backsheet of
the absorbent article 100, to said housing.
[0137] In a preferred embodiment, the flexible connection member 31
has a width that is less than the width w of the insulating layer
200 such that, when connected to the chassis of the absorbent
article 100, said connection member slides between the insulating
layer 200 and the backsheet typically forming pocket for receiving
the same. An advantage of this arrangement is that a secure and
protected connection may be achieved in a simple and cost-effective
manner, resulting further in an optimum design for readily
implementing in fast in-line process of manufacture.
[0138] As shown in FIG. 6A to 6C, the clip-on data processing
module 103 may further comprise an electronic-ink based display 400
for displaying textual and/or graphical indicia 41 generally
relating to the status of said module (such as battery level,
wireless connection with the server and/or cloud and the like),
patient information, and/or sensing status (such as saturation
level of the absorbent article, % risk of leakage at any one point
and the like), said display comprising: a layer of electronic ink
42 including a bi-stable non-volatile imaging material disposed
between an activation layer (or activation grid) 44 and a
transparent electrode layer located above the layer of electronic
ink 42, for activating the layer of electronic ink 42 at particular
locations to display textual and/or graphical indicia 41 on the
surface of the display, wherein the layer of electronic ink 42 does
not require electrical power to maintain the indicia 41 visible. An
advantage of this arrangement is that visual data is provided for
the care giver which allows a status review and/or check directly
at the patient alternatively to or in addition to further modules
and/or graphical user interfaces, whilst at the same time
minimizing the power consumption and overall complexity and size of
the clip-on module.
[0139] Optionally, the electronic-ink based display 400 further
comprises a protective layer 40 positioned such that the layer of
electronic ink 42 is between said protective layer 40 and said
activation layer 44.
[0140] In an embodiment, the display comprises a rigid (e.g.
glass-based thin-film-transistor (TFT)) or a flexible (e.g.
plastic-based TFT) backplane. Exemplary commercially available
displays having rigid backplane for use herein are for example
ED013TC1, ED027TC2, ED029TC1, and/or ED0350C1 manufactured and sold
by E Ink Corporation, a subsidiary of the YFY Group. Exemplary
commercially available displays having flexible backplane for use
herein are for example ET011TT2, ET013TT1, ET014TT1, ET029TC1,
and/or ET014TT6 manufactured and sold by E Ink Corporation, a
subsidiary of the YFY Group.
The Process
[0141] The disclosure herein further contemplates a process of
making an absorbent article comprising the steps of: providing a
liquid impermeable backsheet and applying a plurality of sensor
tracks, as described herein; providing an insulating layer 200
having a width w, taken along an axis perpendicular to the
longitudinal axis y-y, being less than a width W of said backsheet,
and typically applying one or more shortening elements 10 thereto,
optionally further applying one or more secondary shortening
elements 11 thereto; adhering said insulating layer 200 to said
backsheet, said insulating layer being sized and positioned to
cover the at least one central track 4 and optionally a portion of
the at least two side tracks 7,8, to provide a laminated substrate;
providing an absorbent core comprising absorbent material;
providing a liquid permeable topsheet; and sandwiching the
absorbent core between said backsheet and said topsheet.
Preferably, the sensor tracks are in the form of an electrically
conductive ink and the application step comprises the printing
thereof onto the backsheet, preferably wherein the shortening
elements 10 and the secondary shortening elements 11 are in the
form of an electrically conductive ink and the application step
comprises the printing thereof onto the insulating layer 200 or
backsheet.
[0142] In an alternative embodiment, when using a registered sensor
design as explained herein above with reference to FIGS. 7-8,
similar process steps to the above may be carried out except that
the shortening elements 10 and/or secondary shortening elements 11
are not applied to the insulating layer 200 but rather directly to
the substrate 1 (typically being the backsheet). Moreover, the
process generally comprises the step of detecting registered marks
300 to trigger accurate cutting of the substrate 1 (or the
assembled/laminated continuous absorbent article) into a plurality
discrete absorbent articles.
[0143] In a preferred embodiment the width w of the insulating
layer 200 is less than the width W of the backsheet (and/or
substrate 1), preferably is less than 0.5W, more preferably from
0.05W to 0.35W, even more preferably from 0.08W to 0.30W, most
preferably from 0.1W to 0.2W.
[0144] In an embodiment, the layers referred to herein above (i.e.
at least the backsheet and the insulating layer) are in the form of
continuous webs and/or films that are first printed with conductive
ink in the pattern described above (sensor tracks and shortening
elements respectively) prior to being laminated together and
subsequently cut into individual absorbent articles.
[0145] In an embodiment, the insulating layer 200 is adhered to the
backsheet by a non-electrically-conductive adhesive and/or
mechanical bonding, wherein the mechanical bonding is preferably
selected from ultrasonic bonding, thermal bonding, and combinations
thereof. In a preferred embodiment, the adhesive and/or mechanical
bonding is applied across a length and width of the insulating
layer 200 in an effective amount such that bonding is achieved with
the backsheet and a liquid impermeable seal is formed providing a
barrier to exudates expelled by a subject, when wearing the
absorbent article 100, from coming into direct contact with the at
least one central track 4 and the at least two side tracks 7,8,
preferably wherein at a location proximal to the first end 5 of the
backsheet where the clip-on data processing module 103 is to be
connected the adhesive is present only outboard of the at least two
side tracks 7,8 and not therebetween such to form a pocket for
receiving an electrically conducting portion of said module
103.
The Incontinence Management System
[0146] In accordance to an aspect of the disclosure, an
incontinence management system is provided for managing raw data
generated by the modules described herein in cooperation with the
sensor tracks described above and located on a substrate of
respective absorbent articles, and adapted to process the raw data
to processed data, transfer the raw data and/or the processed data
over a network, and link the raw data and/or the processed data
with person data of a given patient or individual. The management
system may comprise a module 103 comprising a transmitter as
described herein above for delivering the raw data (although
processing may also take place within the unit), a cloud server for
processing the raw data to processed data, preferably by applying a
mathematical logarithmic model, and a client application or
graphical user interface for linking the raw data and the processed
data with person data. The management system may optionally further
comprise one or more docking stations for initializing the modules
103 for first time use, the latter may also be done via a portable
device such as a smart phone and/or tablet.
[0147] In a preferred embodiment, the network herein is a wireless
network being a sub-Ghz wireless network (i.e. having data rates of
from 20 kbit/s (868 MHz band) to 250 kbit/s (2.4 GHz band) such as
Zigbee) which is preferred over Wi-Fi that typically operates at
higher data rates (from 2.4 Ghz to 5 Ghz). An advantage of this
arrangement is to provide a large broadcasting distance, low energy
consumption and to remain independent from any existing wifi
networks that for example may be in place at a given institution or
elderly home, so that the system described herein does not need to
share bandwidth with other applications thus improving reliability
and consistency of data acquisition and processing.
[0148] In an embodiment, the disclosure further contemplates an
incontinence management system for managing the measured or
captured data (by the absorbent articles and modules described
herein), thereby using a network wherein the data can be
transmitted, for example anonymized patient data (typically of
relevance for instance in a nursing home or residential care
institution and the like). The measured data or sensor data as used
herein is also referred to as raw data.
[0149] The clip-on modules described herein may comprise a unique
identifier via its media access control (MAC) address which may be
linked to an individual or patient. Preferably, the unique
identifier may be comprised in the form of indicia (e.g. a QR-code)
applied to an external surface of the clip-on modules that may be
scanned by a linking device (such as smart phone or tablet) for
linking a given module to a given individual and/or patient. The
linking may alternatively be done manually by inputting the
identifier number of a given module to the linking device by typing
the same.
[0150] In an embodiment, a plurality of modules as described herein
are connected to the cloud where the sensor data is linked with an
individual or patient, preferably anonymously via numerical
identifiers randomly generated for each individual or patient.
Preferably, the raw data is processed within the cloud wherein one
or more mathematical models may be applied to further compute and
predict a plurality of wetness status, pathological status, and/or
physiological status for each individual/patient. Referring to the
application within a nursing home for instance, a linking dock may
be provided locally in the nursing home, and acting as network
access point and server.
[0151] In an embodiment the network is a wireless network, e.g. a
local wireless network such as wireless local area network (WLAN)
(typically using WiFi.TM.) and/or Bluetooth.TM. for the wireless
connection. Most preferred wireless network however remains Zigbee
as described above, and herein after embodiments that specifically
refer to wifi can be, and are preferably implemented, with Zigbee.
Regarding the use of a unique identifier, a service set identifier
(SSID) is then for instance used over the WLAN and may be provided
by the linking dock. The modules may be linked with the linking
dock prior to each module being installed. Moreover, the linking
dock may provide an initialization and/or setting
startup/installation of the module to pre-set and/or activate it
for use, within this initialization the module is provided with the
unique anonymous individual/patient number, stores this number and
relates this number (typically through a database) with real
patient identification such as a person's name for example. A
client application may further be part of the network, and may be
directly linked with the linking dock, and hence generally a
nursing home patient dashboard. Via the client application, the
linking dock or nursing home dashboard is able to indicate which
module is linked with a particular patient, whereas the real
individual/patient identification is stored in a separate database
that is linked with the linking dock. Real patient information can
be displayed by the client application such as for example a tablet
or smart phone. Such information includes for instance not only a
real person's identification, but also processed data or computed
information from the cloud.
[0152] In an embodiment, the measured data is captured by means of
the module described herein (typically by receiving and processing
resistive and/or capacitance signals through the plurality of
sensor tracks comprised in a substrate of the absorbent article as
described herein). The measured data (comprising raw data) is
subsequently transferred to the cloud by means of a wireless data
transfer (typically via the transmitter present the modules
described herein above). Preferably, the measured data is
pre-processed by the processor comprised in the module and
subsequently transmitted to the cloud for application of the
mathematical model used to predict for example the saturation level
of the absorbent article and/or the risk of leakage. An advantage
of the latter arrangement is that the heavy signal processing and
computing is decoupled from the actual hardware connected to the
absorbent article, thus allowing reduced power consumption and
device complexity which in turns makes for simpler large scale
manufacturing as well as reduced module size for comfort of wear
and handling.
[0153] In an embodiment, the modules are distributed and installed
to the absorbent articles (by connecting to the chassis thereof as
described herein) of the corresponding individuals or patients.
Each module may comprise a visual identification number, e.g.
between 1 and 999 typically displayed on a portion of the display
described herein above. This may be useful when replacing one
module with another for servicing, cleaning and the like for a
given patient, for example when replacing a module the new module
may acquire the identification number of the replaced module either
manually by inputting it directly to the module or preferably
automatically via the client application or graphical user
interface (GUI). In parallel, the GUI may also inform the cloud
server that the unique identifier is now linked to the newly
replaced module.
[0154] In an embodiment, the raw data is communicated to the cloud
server, which recognizes the identifier of the module and links
this data to a unique anonymous identifier of the patient. The
cloud server processes, computes or calculates useful information
from this raw data and makes such information accessible in
graphical representation for different end-users or care givers
using a GUI or client application.
[0155] Preferably, the end-users such as for instance care givers
or other nursing home personnel can connect with the cloud and
extract e.g. the needed information for their typical department.
The data from the cloud is still anonymous and the unique anonymous
identifiers have to be replaced with real names and information.
The client application or GUI accesses the linking dock server such
that the useful information or other cloud data is linked to a real
name of an individual or patient. Thus, the module delivers raw
data linked to a unique identifier, such as e.g. a MAC address. The
cloud server processes such data and links such unique identifier
to a unique person or patient number. The processed data can now be
accessed by a client application. The client application replaces
the unique person or patient number with a real person or patient
identification, including for example information regarding room
number, age, and name.
[0156] It is supposed that the present invention is not restricted
to any form of realization described previously and that some
modifications can be added to the presented example of fabrication
without reappraisal of the appended claims.
* * * * *