AN ABSORPTION BODY, NOTABLY FOR USE IN CASES OF URINARY INCONTINENCE IN WOMEN

Abstract: An absorption body, notably for use in cases of female incontinence and containing a core (1) of a highly absorbent material, said core being entirely or partly surrounded by one or more absorbing layers of material. In order to be able to absorb completely, with a high degree a certainty, urine coming in as a rapid flow, the core (1) in combination is made up as a stable, three-dimensional fibre network in which a highly absorbing pulverulent material, e.g. a cross-linked polymer prepared from a methacrylic monomer, is evenly distributed; the core (1) is provided with several preferably rectilinear, deep channels (2) which are facing the source of the fluid to be absorbed; and the channels (2) in the core (1) have been cut or milled therein at a width of at least 4 mm. and with a least 4 mm. of core material left between each two neighbour channels (2). The absorption capacity may be increased by adding a further layer of absorbent material, e.g. of the same kind as the core material, on the side turned away from the source of liquid.

Description: AN ABSORPTION BODY, NOTABLY FOR USE IN CASES OF URINARY INCONTINENCE IN WOMEN Field of the Invention The present invention relates to an absorption body notably meant for use in cases of urinary incontinence in women, but in principle also .suitable for use as a diaper in other connections and as a dressing material for highly suppurating wounds and as an absorbing material for purulent matter and other liquids led away from, e.g., surgical operations. The absorption body according to the invention, which is of the kind that contains a core of a highly absorbent material, may also find use in some industrial connections, e.g. in chemical laboratories. Background of the Invention Many embodiments of diapers, sanitary napkins and catamenial tampons and similar absorption bodies are known. However, no known construction is particularly suitable for female urinary incontinence, which poses certain quite special demands. The absorption body must be flat, have a modest thickness in the dry condition and have a suitable width. It must be fairly uniform in its entire length and width, firstly so as to not require the exertion of a high degree of precision at its application and secondly so as to cause no harm if displaced while being worn by the user, such displacement being almost inevitable. A particularly important requirement is that the absorption body is able to absorb very rapidly a not insignificant amount of urine. In cases of female urinary incontinence it frequently happens that in a vigorous flow (15-25 ml/sec.) urine flows out for, e.g. 1/2 to several seconds. These amounts of urine should be subject to absorption at once and that with a great certainty against overflow. A total absorption capacity in the absorption body of for instance 70 ml in a number of cases may be considered sufficient, but for some disorders it must be greater. An absorption body for the main purpose stated thus must have properties different from those of sanitary napkins which are to absorb a fluid flowing more constantly and slowly and having a much higher viscosity than urine. It is known to manufacture absorption bodies with a receiving chamber from which urine may be distributed into the core of the absorption body. This has been found, however, to involve the drawback that the urine may have difficulties in being distributed into the entire core because the parts thereof bordering on the receiving chamber are rapidly saturated and thereby reduce the possibility of through-flow. Known sanitary napkins moreover have a tendency to press out the urine when they are compressed in a state entirely or partly filled with urine. It will be understood that an absorption body for the present particular purpose must have a series of properties. One of them is that the abovementioned receiving chamber is replaced by a number of channels - preferably rectilinear and parallel - in the core body responsible for the absorption of the urine. From DK patent specification No. 122,636 there is known a diaper of a highly absorbent material, preferably dry-fibered cellulose, having several depressions (which may be rectilinear and largely parallel) . The depressions have been made by compression and this will be a considerable disadvantage in ah absorption body for the use here contemplated because the compression will slow down somewhat the rate of the absorption of fluid and thereby render the diaper unsuitable for the absorption of such vigorous flow of urine as is usual in the case of incontinence. From the German published specification No. 2 319 309, which is mainly concerned with the kind of the absorbing material (CMC-derivatives), it is known to provide a core with longitudinal, parallel depressions. It appears that they have been formed by embossing, i.e. compression, and thereby have the abovementioned drawback in relation to an absorption body with the purpose here aimed at.- From US patent specification No. 3 343 543 there is known a sanitary napkin provided with troughs for the absorption of liquid. These troughs normally have been formed by compression - with the abovementioned drawbacks in relation to the use here contemplated - but it is stated that they may be formed by cutting although it has not be explained how or for which purpose. It is also stated in that specification that one or more layers of wrinkled or grooved paper may be present in the body of the napkin between its upper and lower faces to retard the flow of fluid to the bottom region thereof, which is stated to ensure total absorption by the upper region of the napkin before a material quantity of the fluid reaches and is absorbed by the lower portion. This measure shows that with this absorbing object one does not attempt at obtaining the fastest possible rate of the absorption of fluid, which presumably is connected with the higher viscosity of the material to be absorbed and perhaps also with the fact that it comes in a relatively slow flow. From US patent specification No. 3 411 504 there is known a sanitary napkin which at the side facing the source of fluid is provided with a ridge situated between two grooves, the ridge being adapted to fit in between labiae majorae in order to ensure against leakage. The grooves are preferably formed by compression, that method being stated to increase the absorption capacity. Such an absorbing object is not either suitable for the purpose aimed at with the present invention, i.a. because there are precizely only two grooves and the object therefore cannot absorb uniformly and evenly over its entire surface. Brief Description of the Invention It is the object of the invention to provide an absorption body that remedies the described drawback in the prior art and represents a combination of properties such that it is particularly suitable for use in cases of female urinary incontinence. This is obtained thereby that the absorption body according to the invention has the following combination of properties: (a) the core is made up in a form of a flat pad by dry-depositing on a thin, coherent, porous layer of material and consists substantially of a. fibrous material of which at least a part constitutes a stable, three-dimensional network as a structure-giving component which is connected with the coherent layer of material and in which " there is evenly distributed a highly absorbent pulverulent or fibrous material, preferably on the basis of cellulose or starch products, cross- linked acrylic or methacrylic polymers or combinations thereof, (b) the core is provided with a number of preferably rectilinear and parallel channels originating from the surface not provided with the thin layer of material and facing in use the source of the fluid to absorb and having a depth of 65-95% of the thickness of the pad, and (c) the channels have been formed by a cutting or milling working of the pad and have width of at least 4 mm, and leave at least 4 mm width of core material between each to neighbouring channels. The principle of dry-depositing materials such as the core in question is well known. It consists in that the material from which the materials are to be prepared is deposited from an air-current on a suitable (optionally removable) support. Some degree of stratification is thereby achieved so that the material becomes somewhat anisotropic, yet not more so than it is justifiable to say that it has a uniform structure throughout the thickness. In the finished product this stratification causes that by moistening and absorption of liquid the pad only expands in the height dimension whereas the width and length dimensions remain substantially unaffected. Such a stability of the flat shape of the absorption body not only is important for the comfort when it is worn but is also important for retaining the open cross-section of the channels after a first absorption of fluid so that the absorption body is ready for possibly absorbing later new liquid at approximately the same efficiency. In preparation the portion of the fibrous material to form the structure-giving component in practive will be present as staple fibres or comparatively short lengths of filaments. This part of the content of the pad according to the invention preferably consists of fibres of a thermoplastic material; polyethylene fibres have proved particularly suitable but even polypropylene fibres are suitable. In principle all thermoplastic fibres may be used only they can be hot-melted within a reasonable temperature range, e.g. 90-175 C. This fibrous material may also be natural fibres or other non-thermoplastic fibres coated with a thermoplastic material. A thermoplastic surface is important. When these fibres have been deposited on the support and afterwards heated to a temperature just sufficient to soften the surfaces of the fibres, the fibres will adhere to each other at the spots of contact, whereby the three- dimensional network mentioned is formed. By the heat treatment also the thin, coherent layer or material contributing to the stiffening of the structure is adhered. This network retains the other components of the pad. The most important one thereof is the highly absorbent material which is sometimes designated (and may be commercially available) with the name . "superabsorber" . Such materials may be either pulverulent or fibrous. As far as is known the first- mentioned form is the most common form of such materials and especially for retaining a powder the three-dimensional network is essential. Several kinds of such materials are on the market. Some forms are based on cellulose or starch derivatives, others on cross-linked polymers of acrylic or methacrylic monomers. One kind of such a material that has proven very suitable for the present purpose is that sold under the name of "Favor" (a registered trade mark) and is supplied by Chemische Fabrik Stockhausen, Krefeld, BRD. This particular material can absorb up to many hundred times its own weight of distilled water. For urine the absorbing power of various kinds of the materials in question is 10-80 times their own weight and the absorbing capacity is not only high but also rapid. However, "Superabsorbers" exist with varying rates of absorption, which afford the possibility of obtaining an optimal effect. The amount of "superabsorber" is typically 1.5-5 g per absorption body. It is known to use these materials in connection with incontinence. The materials are insoluble but highly swellable in water. If desired the termoplastic fibres may according to the invention be supplemented with cellulose fluff which is an inexpansive material having a not small absorbent capacity although it is far from being at a par with cellulose or acryl based "superabsorbers" as just discussed. The next part of the combination according to the invention is the requirement that the channels have a depth of 65-95% of the thickness of the pad. Hereby there is achieved a considerable absorbing surface, viz. not only the face of the pad but also the walls of the channels. When urine flows from the urethra the major portion thereof will at once flow into the channels whereby it is avoided that any portion bypasses the absorption body and wets the legs or underwear of the wearer, and because of the big surface area the urine will immediately be absorbed from the channel walls and bottoms, that is if firstly the above- discussed condition (a) and secondly the condition (c) discussed hereinafter are fulfilled. It is here mentioned that expediently the pad has a thickness of 2-7 mm, e.g. 3-6 mm and preferably about 5 mm. The channels must be formed by a working of cutting or milling, not by compression or embossing. This has several advantages. First and foremost one hereby avoids the compression of the core material mentioned by way of introduction and which will delay the absorption of urine. But moreover it involves an economic advantage because the material cut away, notably the "superabsorber" thereof - which is the most expensive part of the absorption body according to the invention - then may be reused. The cutting must take place after the heat treatment by which the stable structure has been formed. The channels must have a width of at least 4 mm in order to be able to absorb immediately a stream of urine and distribute it to the absorbing channel walls, and there must be at least 4 mm between two neighbouring channels so as to ensure a sufficient amount of material between the channels (plus at the bottoms of the channels) for the absorption. Expediently the channels are about 5 mm wide and have an intermediary ridge having a width of about 7 mm. It will be understood that a rather considerable amount of material is cut away or milled away from the pad after the dry-depositing, in practice normally about 30%, in some cases perhaps as lov as about 25%. Because of the thin, coherent layer of material the core even after the removal of the large amounts of material does have, however, sufficient strength and rigidity to exhibit the appearance of a flat, flexible pad yeat without tendency to fold up in the channels. Description of the Drawing In the following the invention will be described more fully with reference to the drawing in which: Fig. 1 shows a plan view of an absorption body according to the invention, the core being intimated by dashed lines, and Fig. 2 is a section of the absorption body along line II-II in fig. 1. • In the drawing the absorption body according to the invention is shown in a preferred embodiment particularly well suited for use in cases of female urinary incontinence. Inside the body there is a core 1 on which there has been placed various fluid distributing and absorbing layers, and outermost the absorption body is surrounded by a casing 7. The core 1 has been prepared by dry-deposition in a continuous operation, and seen from above it has a rectangular shape as appears from fig. 1. The core may have a width of about 85 mm and a thickness of about 5 mm. The thickness may vary according to the desired absorption capacity and flexibility of the absorption body. The thickness will be between 2 and 12 mm, generally between 3 and 6 mm and preferably 5 mm. The material is normally constituted by a mixture of cellulose fluff, which is a filler having no small ability of absorbing fluids, in an amount of about 38% by weight, about 16% by weight of thermoplastic fibres and about 46% by weight of a socalled "superabsorber" which is a polular name of a class of highly absorbing materials. Such materials may be either pulverulent or fibrous and several kinds thereof are on the market. Some kind are based on cellulose or starch derivatives, others on cross-linked polymers of acrylic or methacrylic monomers. One suitable kind of such a material is sold under the mark "Favor" (registered trade mark) and is supplied by Chemische Fabrik Stockhausen, Krefeld, BRD. Optionally the content of cellulose fluff may be reduced or possibly entirely omitted but normally it is present in an amount as here relative the thermoplastic fibres of 2.5:1. The thermoplastic fibres are mandatory and may be polyethylene fibres, which are particularly suitable, but even for instance polypropylene fibres. In principle all kinds of thermoplastic fibres may be employed, only they can be hot-melted within a reasonable temperature range, e.g. 90-200 *oC. The upper limit of the temperature is normally set by the superabsorber, which often does not stand temperatures above 160 C. The fibrous material may even be natural fibres or other non-thermoplastic fibres coated with " a thermoplastic material. By the dry-deposition the material to enter the core is suspended in an air current and the material is deposited on a length of a thin, coherent, porous material, e.g. paper, the air being sucked off via the pores of the material. This mixture, constituting the core material, by the dry-deposition will be deposited in such a manner that the fibres primarily become oriented in planes extending approximately parallel to the upper and lower faces of the core. It is hereby obtained that the swelling at absorbing fluid into the core substantially takes place in the direction of the thickness of the core and thereby entails the least possible risk that the fluid will be pressed out by a local compression of the body. The core is provided with straight and parallel channels or grooves 2 lengthwise of the upper face of the core. The forming of these channels or grooves 2 normally takes place after the body has been subjected to a heat treatment during which the thermoplastic fibres are heated at such high temperature (e;g. 90- 200°C depending on the thermoplastic material) that in a portion of the points of intersection they fuse to form a three-dimensional lattice having a considerable stability of shape. Normally the superabsorber defines the upper limit of the temperature. The other components are evenly distributed within this lattice structure. This structure in connection with material length 3 melted onto it has a sufficient • strength to allow the channels 2 to be formed by cutting or milling. The channels must have a width of at least 4 mm and there must be at least 4 mm between two neighbour channels. Ordinarily the channels are made at a width of 5 mm and with 7 mm width of the intermediary parts. The channel depth is 65-95% of the thickness of the core. The channels constitute distributing paths for fluid in the body, ensure a considerable increase of the surface through which the fluid can penetrate into the body, and the sides of the channels because of the fibrous structure with the fibres situated in planes approximately parallel with the upper and lower faces form a surface very open to penetration of fluids. The material cut or milled away during the preparation can be re-used in the dry- deposition process for which reason the forming of the channels does not cause waste of the superabsorber, which represents a substantial part of the costs of material for the preparation of the absorption body. By the dry-deposition process the core of the absorption body as mentioned is provided with a paper layer 3. This paper layer contributes at distributing the fluid and in itself is even able to absorb part of the fluid. However, the most important function of the paper is to keep the core together during and after the milling of the channels 2. Because of the paper layer 3 the tendency of the absorption body to become squeezed together from the sides is reduced and the paper layer thereby contributes at keeping the channels open. Below the paper 3 there may be placed a highly absorbing layer 4 of material, which layer may also be prepared as a length by dry-deposition of a mixture consisting of about 35% by weight of fluff, about 15% by weight of thermoplastic fibres and about 50% by weight of superabsorber. At a thickness of 1.5 mm this 2 length will have a weight of about 350 g/m in contradistinction to the core proper, which at a thickness of 5 mm will have a weight before milling 2 • of about 550 g/m . The layer 4 has the purpose of increasing the absorption capacity and it may have various shapes such as hour-glass shape or the like. In this manner it is possible to ensure an optimum capacity at the ends of the absorption body. The superabsorber is chosen with such moderate rate of absorption that the fluid will have time to spread over a substantial portion of the area of the absorption body, so as to utilize the capacity comparatively uniformly, and the absorption body better becomes able to receive a number of brief flows of urine at some intervals of time. If a particularly high absorption capacity is not needed, the highly absorbing layer 4 may be dispensed with entirely or partly. If a particularly high absorption capacity is needed, the absorption body may be rendered both thicker and bigger. It may be rendered so much bigger that at the ends of the core it extends outside the contour thereof, whereas at the middle it is somewhat narrower than the core. According to an economic embodiment the highly absorbing layer may be replaced by or supplemented with a diaper of cellulose fluff the major parts of its volume being placed at the ends of the core. Hereby the total absorption capacity may be increased at 200-500 ml corresponding to the entire content of a full urinary bladder. In this embodiment the distributing properties of the core is utilized to a high degree whereas the absorbing capability of the core, in itself big, contributes at absorbing the entire amount of urine. Since in the area between the legs of the wearer substantially only the distributing core of the absorption body is present, this form of a diaper is considerably more comfortable than traditional diapers. At the normal absorption capacities of for instance about 70 ml, there is especially attached importance to the comfort and to the circumstance that the absorption body is to be part of a napkin which despite ' a big absorption capacity must be so compact that the user does not in dressing need to pay any regard to the napkin. The core 1 and the optional highly absorbing layer 4 are thereupon wrapped in one or more layers 5 of paper of which one or more layers may have been led down to the bottom of the channels 2 to which it may be secured by the aid of glue or the like. During the preparation of the absorption body this pressing down may take place by the aid of rollers or the like. The purpose of this or these layer(s) of paper is firstly to contribute at distributing the fluid throughout the surface of the body, instead of the fluid being possibly pressed through the core without being absorbed, and secondly to keep the pulverulent superabsorber material within the- core material. Preferably the paper is only fixed at the bottoms of the channels because this has importance for the expansion of the core and for the comfort when the absorption body is worn against the skin of the user. On the under side the absorption body is furthermore provided with a liquid-tight layer 6 preventing seeping out of fluid. Outermost the absorption body is enveloped in a non-woven material layer' 7 which is skin-friendly and which encloses the absorption body in a closed bag. Absorption bodies for use in cases of female incontinence are severed in lengths of about 180. mm, which severing as shown in fig. 1 may be straight but which may also be curved. In the latter case the core material and highly absorbing material 4 cut off may be re-used. At the ends 10 the envelope is closed by glueing, hot melting or the like. The finished absorption body if needed may be provided with a commonly known adhesive layer 8 at the lower face whereby the absorption body may be maintained as an ordinary napkin in the pants of the user. The adhesive layer in known manner may be covered by a releasable silicone coated cover 9. Although the absorption body according to the invention mainly is described as a protection in cases of incontinence, for which purpose its ability to absorb very rapidly not insignificant amounts of fluid released in one or more comparatively short but 'comparatively strong flows is indispensable, it is within the framework of the invention to use the absorption body for absorbing other human secretions, and the shape and the size of the body may be varied according to need. As examples of such uses may be mentioned diapers, sanitary napkins and wound dressings, but even purely technical uses may come into consideration.

Claims: Patent Claims 1. An absorption body, notably for use in cases of urinary incontinence in women and containing a core of a highly absorbent material, said core optionally being entirely or partly surrounded by one or more layers of absorbing material, characterized by the following combination of properties: (a) the core is made up in a form of a flat pad by dry-depositing on a thin, coherent, porous layer of material and consists substantially of a fibrous material of which at least a part constitutes a stable, three-dimensional network as a structure-giving component which is connected with the coherent layer of material and in which there is evenly distributed a highly absorbent pulverulent or fibrous material, preferably on the basis of cellulose o starch products, cross-linked acrylic or methacrylic polymers or combinations thereof, (b) the core is provided with a number of preferably rectilinear and parallel channels originating from the surface not provided with the thin layer of material and facing in use the source of the fluid to absorb and having a depth of 65-95% of the thickness of the pad, and (c) the channels have been formed by a cutting or milling working of the pad and have a width of at least 4 mm, and leave at least 4 mm width of core material between each two neighbouring channels. 2. An absorption body according to claim 1, characterized in that a thin, absorbing layer of material, preferably of porous paper, as a casing surrounds the core on all sides and has been led down into the channels to their bottom. 3. An absorption body according to claim 1 or claim 2, characterized in that the fibrous material entirely or partly consists of fibres of a thermoplastic material. 4. An absorption body according to claim 1 or claim 2, characterized in that the fibrous material entirely or partly consists of natural fibres or other non- thermoplastic fibres coated with a thermoplastic material. 5. An absorption body according to claim 1, characterized in that the fibrous material partly consists of cellulose fluff. 6. An absorption body according to anyone of the preceding claims, characterized in that the fibrous material consists of a mixture of thermoplastic fibres and cellulose fluff in a ratio by weight of about 2.5:1. 7. An absorption body according to anyone of the preceding claims, characterized in that the core consists of 40-50% by weight of pulverulent or fibrous, cross-linked acrylic polymer, 10-20% by weight of thermoplastic fibres and 30-50% by weight of cellulose fluff. 8. An absorption body according to anyone of the preceding claims, characterized in that the thin, absorbing layer of material surrounding the core on all sides and preferably consisting of paper has been secured, preferably adhesively, to the bottoms of the channels and only to these. 9. An absorption body according to anyone of claims 2-8, characterized in that a flat, highly absorbent layer of fibres and fibrous or pulverulent cross-linked polymer has been placed between the core and the casing, on the side of the core adapted to be turned away from the source of liquid, said layer having a lesser thickness than the core. 10. An absorption body according to claim 2, characterized in that the flat, highly absorbing layer of material consists of 40-60% by weight of fibrous or pulverulent cross-linked polymer, 10-20% by weight of thermoplastic fibres and 30-40% by weight of cellulose fluff. 11. An absorption body according to claims 1-8, characterized in that a diaper of cellulose fluff has been placed on the side of the core adapted to be turned away from the source of liquid, said diaper being longer than the core of the absorption body and at least at the ends wider than the latter.

Inventors: KAMSTRUP-LARSEN JOERGEN, KAMSTRUP-LARSEN, JOERGEN
Applicants: COLOPLAST AS, COLOPLAST A/S
Application year: 1985
Main classification: A41B13
IPC codes: A61F5, A61F13