UNDERPANTS WITH AN INSERT

Abstract: The preferably multi-layer exchangeable disposable insert (22) of the multi-reusable, washable underpants (12) for slightly to severely incontinent children or adults comprises at least one absorbent material. There is fastened unreleasably in the appropriately cut-out or shaped, preferably deep-drawn crotch region of the underpants (12) an anatomically preformed crotch basin (14) which corresponds to their size and which serves as a waterproof supple outer layer for an exchangeable fluid-permeable insert (22) designed as a three-dimensional absorbent body (24) shaped according to the anatomy. This disposable insert (22) matches the body weight, sex and/or the degree of incontinence. The inserts (22) are ecologically sound cheap products with appreciable wearing confort which are inserted into the crotch basin (14) without further aids and which afford increased safety against escape and slipping out of place.

Description: f Underpants with an insert The invention relates to multi-reusable, washable under¬ pants with an exchangeable fluid-permeable disposable insert consisting of at least one absorbent material for slightly to severely incontinent children or adults. Incontinent persons who have to wear inserts of absorbent material rely on external moisture protection which prevents the underclothing and outer clothing from becoming wet. This moisture protection is often designed as protective pants or napkins which are impermeable to fluids or permeable to them only in vapour form. Sheet¬ like inserts of essentially rectangular form having indentations on the long sides and with an absorbent pad for continuously and/or suddenly flowing out body fluids are likewise in common use. Such an absorbent pad is enveloped in a fluid-permeable layer next to the body during use and in a fluid-impermeable layer remote from the body. In an attempt to permit absorbent pads to be made as light, thin and supple as possible, chemical absorption agents of high absorbency are incorporated. The so-called superabsorbers, namely polymers of high absorption activity which are obtainable in the trade and which can bind a multiple of their own weight of urine or saline water, are of particular importance in this respect. With these, a gel is formed, and this remains stable even under the effect of pressure. It is known, moreover, further to increase the retention of an absorbent pad, that is to say the prevention of the expulsion of fluid under the effect of pressure, by providing a thermal binding. For this, the cellulose-containing fibrous down has admixed with it a further fibrous down consisting of a thermal plastic which, at an increased temperature, acts at particular points as a hot-melt adhesive. Finally, there are known inserts which have an outer moisture-impermeable layer in the form of a supple shell. This shell constituting a container affords additional safety especially to adult persons who suffer from a sudden flow of urine. The shell is normally equipped with fastening tapes which can be fastened to the body and/or to the underpants. The externally waterproof shell can also be fastened in the underclothes by other known means, for example, a holder fastened to the underclothes and arranged on at least two sides and/or adhesive strips extending in the longitudinal direction on the outer face of the shell and having a tear-off protective strip. The disadvantage of these incontinence inserts with a • moisture-proof shaping shell is that they are non-decom- posable and therefore cannot be changed at every occa¬ sion. For example, they ought not to be thrown into a lavatory bowl, but must always be deposited in waste bins which are often open. Persons suffering from severe incontinence with the excretion of faeces therefore easily find themselves in an embarrassing predicament. Furthermore, because of its flat, virtually two-dimen¬ sional form brought about by being pulled up, a shell adhesively bonded releasably to the underpants cannot offer a reliable guarantee against escape or, for example during sports activities, can easily slip out of place and come out of its ideal position. When short leg clothing which is extremely popular in leisure time and for sports activities is worn, the shell can even become visible. US-A-4,568,341 describes numerous versions of longitudin¬ ally folded inserts for slightly incontinent persons, which are inserted into underpants and which are fastened to a fluid-permeable underlay glued in or sewn in. This underlay is of two-layer design and rests in the underpants in the crotch region. The advantage of this system having reusable washable underpants with a disposable insert is that not every insert has to be equipped with a relatively thick water-impermeable layer (30 to 50 μ ) . However, complicated manipulations are necessary, and as before there is only a low degree of safety against an escape. The object on which the present invention is based is to provide underpants with an insert of the type mentioned in the introduction, which offer individually to slightly and doubly incontinent persons of any age and sex an increased wearing comfort, greater safety and fewer disposal difficulties when the insert is exchanged. Furthermore, the underpants with the insert will be ecologically sound, free of problems and cost-effective. The object is achieved, according to the invention, in that the disposable inserts consist of a three-dimen- sionally shaped free-form absorbent body matching the body weight, sex and\or the degree of incontinence, which absorbent body is arranged so as not to slip out of place in an appropriately cut-out or shaped crotch region of the underpants in an anatomically performed crotch basin which corresponds to the size of the said body and which is waterproof, supple material. The shaping of the underpants in the crotch region is preferably achieved by deep-drawing. A preformed fluid-impermeable shell, here called a crotch basin, is therefore an integral part, not of the insert designed as a disposable article, as is usually customary according to the known state of the art, but of the underpants which can be washed after use and worn again. This is economical on the one hand, but on the other hand also affords even more important advantages: - an incontinent person can dispose of a used insert with little effort and replace it with a new insert which can be carried with him within a small volume. The insert inserted into a crotch basin fastened unreleasably to the cut-out or deep-drawn crotch region of the underpants cannot slip out of place during use, even during intensive sports activities. - An incontinent person can wear not only all types of conventional underclothes with an unreleasably intro¬ duced crotch basin, whether briefs or underpants with short or * long leg extensions, but also pyjama bottoms, bathing trunks and the like, and the crotch basin can be camouflaged accordingly. Conventional or special underpants, for example consist¬ ing essentially of cotton with elastic properties, can, instead of being cut-out, also be deep-drawn in -the . crotch region. In a way known per se, the crotch region of the underpants is pressed with heating by a shaped xam into a shape corresponding to the crotch basin. After pressure is removed, the underpants have a shaped-out portion corresponding to the crotch basin and intended for receiving an insert. In comparison with US-A-4,568,341, the solution according to the invention has the following advantages: - - The absorbent body has a stable and three-dimensional shape preferably with an inner face matched anatomic¬ ally to features specific to the particular sex. The dimensions can be matched to the body weight and/or the degree of incontinence. For production, in the shaping station the absorbent body according to the invention is first brought into the final form, including any slits and depressions. The absorbent body is then thermal-bonded, the plastic fibres melting down and, after cooling, many connect¬ ing points with the cellulose fibres forming. Because the crotch basin is not pressed flat when the underpants are put on, there is no danger of escape and there is no need for fastening means for the insert. The absorbent body merely has to be inserted, no further aids being necessary. There is nevertheless no possibility of it slipping out of place while it is being worn. The crotch basin is fastened unreleasably to the under¬ pants by methods known per se, for example by means of being sewn in and/or glued in, especially by means of hot-melt adhesion. The cellulose fibres are recycled from waste paper and/or cotton waste especially advantageously in economic and ecological terms. The waste is appropriately broken open by means of a hammermill, converted into fibre flakes and intimately mixed with 3 to 12 % by weight of plastic fibres. The preformed crotch basin which is fastened unreleasably to the underpants and which forms a recess and should allow moisture to permeate at most in the form of vapour, preferably consists of a soft plastic, especially also polyurethane or polyethylene, or of a fabric impregnated with a plastic. Plastic foams customary for shells are suitable only in a particular quality for crotch basins because of the frequent washing of the underclothes. The soft hydrophobic materials guarantee an appropriately comfortable fit for the three-dimensionally shaped insert. Particularly a severely incontinent or even bed-ridden person, who cannot control either his urine or faeces has to wear underclothes which, in order to be put on and taken off, but also for the exchange of the insert, possess means, known per se, for lateral closing and opening which are operated by a nurse. In this case, a crotch basin fastened unreleasably to easily opened underpants, also known as multi-pants, is especially important. The shaped three-dimensional absorbent body preferably consists of cellulose fibres connected at particular points to thermoplastic fibres and of spread-in super- absorbers. Absorbent bodies are produced by special shaping stations, for example according to WO The insert for the underpants which is preferably formed as a multi-layer, three-dimensional absorbent body is usually enveloped on both sides in fluid-permeable supple films. A softer layer next to the body during use and a firmer shapeable layer remote from the body are possible, but not necessary. The layers preferably of a thickness of 1 to 5 μm are markedly thinner than those customary hitherto, even when the layer facing away from the body during use is water-impermeable. The absorbent body contains, in addition to cellulose and/or cotton fibres, for example approximately 1.5 to 18%, preferably approximately 6% of plastic fibres and approximately 10 to 15% of superabsorbers (each in % by weight) . The plastic fibres used consist preferably of a poly- olefin or of a polyester. Examples of materials of plastic fibres are polyethylene, polypropylene, copoly- mers of ethylene and propylene and copolymers of pro- pylene and butylene. The plastic fibres mixed with the cellulose-containing fibres have, as a rule, a diameter of 1 - 40 μm, espe¬ cially 5 - 20 μm. It has proved especially advantageous to mix cellulose- containing fibres with fibrillated polyethylene. A product of Messrs. DUPONT known by the tradename of "PULPLUS" consists, for example, of fine fibrils of a thickness of 1 - 20 μm which, under heat treatment, form numerous connecting points with the cellulose fibres. In addition to the very small diameter, these plastic fibres have, among other things, a high strength, orientation and unit surface and are easily meltable and workable, chemically inert, environmentally safe and cost-effec¬ tive. Three-dimensional absorbent bodies formed from the fibre mixture and having thermally-connected plastic fibres possess further advantageous properties in addition to the anatomical matching of the inner face: - Avoidance of the use of a series of semi-finished products, such as a waterproof outer wrapping and a polypropylene nonwoven as an inner wrapping on the absorbent body, hot-melt adhesive as an adhesive binder, tape as a hip fastening, waterproof ilm as an escape barrier in the waist region and elastic threads as an escape barrier in the leg region, - A higher retention capacity for fluids (retention), - An improved retention capacity for the powdery super- absorber, Increased dimensional stability, whilst preserving the elasticity, - A greater strength before and after wetting. The heat treatment for the hot-melt adhesive bonding of the plastic fibres at particular points is preferably carried out at a temperature just below the combustion temperature of cellulose, especially at 160 - 220°C. Attention is drawn to the applicant's Swiss Patent Specification for both the process and the appa- ratus. The cellulose-containing fibres of the absorbent pad are advantageously mixed not only with plastic fibres, but also with a chemical absorption agent, especially with a superabsorber. The absorption agent, especially a super- absorber / can optionally also be distributed as homogeneously as possible in the pulp after the heat treatment. The absorption rate of a superabsorber mainly depends on its grain size, that is to say, with relatively small grains, the entire surface of the superabsorber is larger and the absorption or gel formation therefore takes place substantially more quickly. The setting of the absorbency of an absorbent layer is obtained by means of varying and/or different quantities of superabsorbers. The following products are used, for example, as super¬ absorbers: Aridall 1125 of Chemdal, USA Drytech 510 of Dow Chemical, USA PR 9910 S of Floerger, USA FAVOR 922 SK of Stockhausen, FRG If an absorption agent contains thermoplastic fibres, for example fibrillated polyethylene (see, for example, US-A-4,458,042) , there is no need for the separate addition of plastic fibres. The plastic fibres contained in the absorption agent can bring about a sufficient consolidation of the fabric during the heat treatment. The invention is explained in more detail by reference to the exemplary embodiments which are illustrated in the drawing and which- are also the subject of dependent patent claims. In the diagrammatic drawings - Figure 1 shows a view of underpants with an inserted crotch basin, - Figure 2 shows a partial section through the crotch region of Figure 1 with an insert, - Figure 3 shows an insert for slightly incontinent persons, - Figure 4 shows a section IV - IV of Figure 3, - Figure 5 shows an insert for severely incontinen persons , - Figure 6 shows a section VI - VI of Figure 5, - Figure 7 shows a perspective representation of an insert for severely incontinent persons, - Figure 8 shows a representation of a production programme for inserts, - Figure 9 shows an insert with a multi-layer absor¬ bent body, Figure 10 shows a view of underpants designed, as multi-pants, and Figure 11 shows a perspective view of a cardboard box for sales purposes. The underpants 12 which, according to Figure 1, are drawn over a clothes dummy 10 possess, in the crotch region, a moisture-impermeable crotch basin 14 which is preformed anatomically. A cutout 18 (Figure 2) corresponding to the crotch basin 14 is removed from the crotch region of the underpants 12. The orifice edge of the cutout in the underpants 12 and the edge of the shell 14 are connected unreleasably to one another by heat sealing. Figure 2 shows the crotch region of the clothes dummy 10 enlarged and in section. The underpants 12 rest against the legs 16 of the clothes dummy 10. The cutout 18 in the crotch region of the underpants 12 is represented by a broken line. This broken line is also intended to indi¬ cate that, according to another version of the underpants 12, the crotch basin 14 can be deep-drawn in the crotch region, thereby forming a widening for the crotch basin 14. The region 20 connecting the crotch basin 14 to the cutout 18 of the deep-drawn indentation in the underpants 12 is continuous, and as already mentioned it takes the form of a seam and/or an adhesive bond. Inserted into the crotch basin 14 is an insert 22 which consists of a shaped three-dimensional absorbent body 24, of a layer 26 next to the body and of a layer 28 remote from the body. The underpants 12 have an elastic band 62 on both sides at the leg root. A continuous fluid-impermeable edge 44 (Figures 5 to 7) can engage over the leg root and be pressed down by the elastic band 62. It is evident from Figure 2 that, when the underpants 12 are put on, the insert 22 rests closely against the body and is secured in the crotch basin 14 which is non- deformed, especially not pressed flat. The insert 22 can easily be exchanged, and the preformed waterproof crotch basin 14 which is an integral part of the underpants 12 ". also preserves its effect in full for the new insert * 22. The insert 22 illustrated in Figures 3 and 4 has a formed-in longitudinal slit 30 extending in the middle. This is made relatively narrow and reaches into the region of the layer 28 remote from the body. For an incontinent person of the male sex, the longitudinal slit 30 is made longer, this being represented by a broken line 32. If body fluid suddenly flows out, the longitudinal slit can receive the urine without immediate absorption and distribute it. Absorption takes place only gradually. The absorbing capacity can be increased by making a plurality of approximately parallel longitudinal slits. The insert 22 is placed in an appropriately shaped moisture-impermeable crotch basin 14 (Figure 2). The layer 28 remote from the body is made fluid-impermeable in contrast to the layer 26 next to the body. The layer 28 which, however, can also be omitted or made moisture- permeable is 1 to 5 μm thick and sprayed on or formed as a coating. The advantage of this is that the inserts need not have a relatively thick outer layer used once only and difficult to dispose of, and this is also important in ecological terms. Two grip tabs 34 attached to the end faces make it easier to exchange the insert 22. In the embodiment according to Figures 5 and 6 too, the three-dimensionally shaped absorbent body of the insert 22 has a formed-in longitudinal slit 30. However, this is no longer designed as a straight longitudinal groove, as in the two preceding Figures. In the front region, the insert 22 has three slits 36 distributed in the form of fingers and having webs 42 located ' between them. The middle slit 36 corresponds to the longitudinal slit 30. The larger number of slits with an increased absorbent surface makes it possible to intercept a larger quantity of body fluid suddenly flowing out and to absorb it continuously thereafter. In the region of the rear half of the insert 22, the slit 30 widens to produce a formed-in depression 38. The longitudinal slit 30 together with the slits 36 and the depression 38 is covered by an easily removable waterproof layer 40. This layer is knocked mechanically into the recesses after the slits 36, the longitudinal slit 30 and the depression 38 have been formed. A wide continuous edge 44 remains. During the knocking in, the easily removable waterproof layer 40 is connected at few points to the layer 26 next to the body. The easily removable layer 40 can therefore be grasped at the wide edge and easily pulled off from the remaining insert 22. The wide edge 44, projecting from the insert 22, of the easily removable layer 40 is appropriately made water- repellant. This ensures an effective protection of the underpants 12 (Figures 1 and 2) against soiling. If a person is severely incontinent, the depression 38 can fill with faeces. The easily removable layer 40 can then be grasped at the edge 44 or at grip tabs (not shown) , removed with ease and thrown into a lavatory bowl. The remaining insert can be disposed of in the way described above. This gives the incontinent person the inestimable benefit of reducing the necessary manipula¬ tions and danger of soiling to a minimum and of not having to throw the faeces into a bin, which often leads to problems of hygiene. It may also be mentioned, in addition, that inserts 22 dissolving in water can also, be thrown into any lavatory bowl. According to an alternative version (not shown) , the wide edge 44 can be made in one piece with a water-impermeable layer 28 remote from the body and, in interaction with the elastic band 62 according to Figure 2, form an effective moisture barrier. In this case, there is three¬ fold safety against the escape of moisture: - the layer 28 of the insert 22 remote from the body, - the crotch basin 14, and - the seal formed by the edge 44 and the elastic band 62. Figure 7 shows the three-dimensionally shaped embodiment of an absorbent body 24 constituting the insert for babies and doubly incontinent persons. The substantially smaller front part 48 of the absorbent body 24 has four deeply formed-in slits 36 with webs 42 located in bet¬ ween. A voluminous depression 38 is formed in the rear part 50. The widely projecting edge 44 of the rear part 50 is covered with a knocked-in easily removable tissue 40 which is waterproof and which can easily be pulled off. According to a preferred version, the edge 44 is formed on all sides, also laterally and round the front part 42. If a large quantity of urine suddenly flows towards the absorbent body 24 in the direction of the arrow 52, it is immediately distributed in the slits 36 and also the depression 38. The fluid is thereupon absorbed, this being represented by arrows 54. Figure 8 illustrates graphically an extract from an insert production programme. The volumetric ratio G of the longitudinal slit 30, slits 36 and depression 38 to the absorbent pad 24 is plotted on the abscissa and the size of the insert on the ordinate K. It is presupposed, here, that the outer dimensions of the insert correspond approximately to the body size. The insert 22a is intended for slightly incontinent small children and has only one longitudinal slit 30. The insert 22b is intended for a large slightly incon¬ tinent person, and the large insert 22b likewise has a single longitudinal slit 30. The insert 22c is intended for a fairly small woman, the longitudinal slit 30 having extensions to form a depres¬ sion 38. The insert 22d is intended for a moderately incontinent child, and the longitudinal slit 30 formed at the front merges at the rear into a depression 38. The insert 22e is used for a baby or a severely incon¬ tinent small child and has a longitudinal slit 30 and a depression 38. The insert 22f for a severely incontinent adult person corresponds to Figures 5 to 7. All the inserts contained in the production programme can be incorporated in a representation according to Figure 8. The insert 22 shown in Figure 9 has an absorbent body 24 built up in layers. The uppermost layer 24a covered by the layer 26 next to the body has a lower content of absorption agent than the layer 24b second from the top. The layer 24c arranged under it has the highest content of superabsorber. Thereafter, in the layers 24d and 24e, the content of superabsorber decreases again. According to one version, the layers 24c to 24e arranged underneath the layers 24a and 24b each have alternately a lower and a higher content of absorption agent. Attention is also drawn to Swiss Patent Specification , for further details regarding layered absorbent bodies 24. With all the embodiments according to Figure 9, there is, in particular, only a very slight backflow wetness, and the insert is therefore always felt to be dry. All the inserts 22 shown in Figures 2 - 7 and 9 are ecologically sound cheap products which, moreover, give an incontinent person greater wearing comfort and an increased feeling of security. The inserts comprise an agreeably close-fitting layer 26 next to the body, a soft absorbent pad 24 and a preformable, but nevertheless soft layer 28 remote from the body. In addition to otherwise conventional underpants, espe¬ cially made of elastic cotton, which are cut-out or deep- drawn in the crotch region, multi-pants 56 of a type known per se, according to Figure 10, can also be used for the unreleasable fastening of a crotch basin 14 forming the recess for an insert. The outer skin 58 consists of elastic cotton and the inner skin 60 of cotton. The leg root is equipped with an elastic band 62 which, as shown above, seals effectively in interaction with a wide edge 44 (Figure 5 to 7). The multi-pants 56 are simple to close by means of instant-grip fastenings and to open again. Sales boxes 64 shown in Figure 11 and with a handle 66 and a tear-open thread 68 are especially advantageous for the manufacturer, retailer and consumer. After the tear- open thread 68 has been removed, a lid 70 can be swung open and closed again. The inscribable sales box contains a pair of underpants with a crotch basin and a relatively large number of inserts, for example 24 to 48. The sales box allows presentation, transport and storage in the smallest possible space, can be kept in a shopping bag and is suitable for extracting the inserts one by one which are easily accommodated individually in any hand¬ bag.

Claims: Patent Claims 1. Multi-reusable, washable underpants with an ex¬ changeable fluid-permeable disposable insert (22) consisting of at least one absorbent material for slightly to severely incontinent children or adults, characterized in that the disposable insert (22) consists of a three-dimensionally shaped free-form absorbent body. (24) matching the body weight, sex and/or the degree of incontinence, which absorbent body is arranged so as not to slip out of place in an appropriately cut-out or shaped crotch region of the underpants (12) in an anatomically preformed crotch basin (14) which corresponds to the size of the said '. body and which is of waterproof, supple material, . * 2. Underpants according to Claim 1, characterized in that the crotch region is deep-drawn. 3. Underpants according to Claim 1 or 2, characterized in * that the three-dimensionally shaped absorbent body (24) consists of a pulp with cellulose-containing fibres, thermoplastic fibres and a spread-in super¬ absorber. 4.' Underpants according to one of Claims 1 to 3, charac¬ terized in that the three-dimensionally shaped absor¬ bent body (24) is of multi-layer design, the inner layer or inner layers preferably containing more superabsorber than the outer layers. 5. Underclothes according to one of Claims 1 to 4, characterized in that the cellulose fibres of the three-dimensionally shaped absorbent body (24) are recycled from waste paper and/or cotton waste and are preferably connected at particular points to poly¬ ethylene fibrils. 6. Underpants according ' to one of Claims 1 to 5, characterized in that the crotch basin (14) consists of a soft plastic, especially polyurethane or poly¬ ethylene, or of a fabric impregnated with a plastic. 7. Underpants according to one of Claims 1 to 6, charac- terized in that the shaped three-dimensional absorbent body (24) is enveloped on both sides by thin supple layers (26, 28), preferably by a softer layer (26) next to the body during use and a firm shapeable layer (28) remote from the body. 8. Underpants according to one of Claims 1 to 7, charac¬ terized in that the layers (26, 28) enveloping the shaped three-dimensional absorbent body (24) are 1 to 5 μm thick, and the absorbent body (24) preferably contains approximately 1.5 to 18%, especially approximately 6% of plastic fibres and approximately 10 to 15% of superabsorber. 9. Underpants according to one of Claims 1 to 8, charac¬ terized in that the insert (22) has a wide continuous edge (44) which is waterproof and which, in interac- tion with an elastic band (62) arranged on the under¬ pants (12) , forms a leg root seal. 10. Underpants according to one of Claims 1 to 9, charac-. terized in that the shaped three-dimensional absorbent body (24), on the side next to the body during use, has at least one formed-in " longitudinal slit (30) which is also widened in the manner of a depression in one longitudinal half of the absorbent pad (24) and/or is made multi-part, with webs (42) located in between, in the other longitudinal half. 11. Underpants according to Claim 10, characterized in that a shaped three-dimensional absorbent body (24) with a depression (38) is covered, on the side next to the body, with a pressed-down easily removable layer (40) which is fluid-permeable and soft, but waterproof, is knocked into the longitudinal slit (30), slits (36) and a depression (38) and has grip tabs (34) projecting preferably at at least three locations.

Inventors: LEONE DEMETRIO, LEONE, DEMETRIO
Applicants: LEONE DEMETRIO, LEONE, DEMETRIO
Application year: 1990
Main classification: A61F5
IPC codes: A41B13, A61F5, A61F13