Abstract:
The teachings herein are directed to devices for detecting and signaling the presence of urine or another electrically conducive liquid in an undergarment, fabric, or other thin material. Preferred devices include a clip configured to safely and releasably secure a liquid detecting sensor to a fabric or undergarment, wherein said sensor is operably coupled to a detection device that emits a notification signal when liquid is present in the fabric.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application 60/959,815 filed Jul. 17, 2007, and is a continuation-in-part of U.S. Non-Provisional application Ser. No. 12/218,698, filed Jul. 17, 2008, now abandoned both of which are expressly incorporated by reference herein in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The embodiments herein generally relate to novel clips and a wetness sensor configured to safely and securely releasably attach to a fabric, such as an undergarment. According to more preferred embodiments, the wetness sensors provided herein are configured to electronically communicate, via a cord or wirelessly, to a notification component adapted to emit an alarm when wetness is detected in the fabric. 
     BACKGROUND OF THE INVENTION 
     Wetness detection sensors configured to work with notification components are known in the art and are useful in helping a user deal with incontinence. The sensor is configured to detect wetness in or around a fabric such as an undergarment and is in electronic communication with a notification component configured to emit an alarm (e.g., audio, visual, or vibratory) to alert the wearer when wetness is detected by the sensor. If the user is sleeping as they begin to urinate in their clothing, the alarm will wake them up quickly so they can finish urinating in a toilet instead of on themselves. 
     Unfortunately many problems exist with the current systems. For example, some sensors do not have adequate means for safely and securely releasably attaching to a fabric. This is an important problem because if the sensor is not securely and effectively fastened, it will not be able to detect the presence of liquid in the fabric. Likewise, many fastening devices are inadequate as they can cause injury or pain to the user. An additional problem in the current systems is that the non-sensing electronic elements on the wetness sensors are often not adequately protected from the urine. A further problem is that some sensors are not configured to be quickly and adequately cleaned for re-use after coming into contact with urine. Accordingly, it is an objective of the present invention to provide a single wetness detection device that overcomes these problems in the art. 
     SUMMARY OF THE INVENTION 
     Preferred embodiments are directed to a device for sensing a conductive liquid in a thin material and comprising: (a) a liquid-sensing printed circuit board (PCB), wherein the PCB comprises an electrode assembly having means for detecting a conductive liquid in the thin material based on a change in electrical resistance in the electrode assembly and means for emitting an electronic signal when the liquid is detected; (b) a resilient overmold body partially molded over the PCB such that it covers the means for emitting an electronic signal while allowing exposure of the means for detecting a conductive liquid; and (c) a clip configured for clamping and unclamping the PCB to the thin material and having a proximal area pivotally hinged to the overmold body and a distal area configured to releasably hold the fabric in contact with the electrode assembly. 
     Further embodiments are directed to devices where a portion of the clip comprises a plurality of retruded teeth pointed toward the resilient overmold body. Advantageously, the teeth are retruded such that they are parallel to the PCB, or substantially so, when the clip is clamped to the PCB. Preferably, the clip&#39;s distal area comprises a generally planar gripping surface configured to press the fabric in contact with the electrode assembly and a plurality of retruded teeth arranged in a row. Advantageously, at least one tooth is coplanar with the gripping surface of the clip, or substantially so. 
     According to preferred embodiments, the resilient overmold body gradually rises up in a distal direction from the proximal area of the PCB to form a knuckle and then steeply descends to a leveled, or substantially so, thin lobe portion positioned on the surface of the PCB such that it protrudes distally away from the hinged knuckle and is configured to engage the thin material against the clip when in a clamped down position. Preferably, the lobe portion comprises a bump, that can be positioned medially and distally on the lobe portion of the resilient overmold body. 
     Further embodiments are directed to a device configured for clamping onto a thin material, comprising: (a) a rigid base layer, having proximal and distal areas, a topside and a bottom side; (b) a resilient overmold body molded over the rigid base layer&#39;s proximal area while allowing substantial exposure of the distal area; and (c) a clip configured to be movable into an open and closed position with respect to the rigid base layer and having a proximal area pivotally hinged to the overmold body and a distal area comprising a gripping surface and a plurality of retruded teeth configured such that the gripping surface presses the thin material into the distal area of the rigid base layer and the teeth engage the thin material. 
     Advantageously, the overmold body covers the proximal areas of both the topside and bottom-side of the rigid base layer. The overmold body advantageously gradually rises up in a distal direction from the proximal area of the rigid base layer to form a knuckle and then steeply descends to a leveled, or substantially so, thin lobe portion. The lobe portion of the overmold body can comprise a bump positioned distally and medially on the lobe portion. The retruded teeth can be configured to be parallel or substantially so with the rigid base layer when the clip is in the closed position. 
     Still further embodiments are directed to a device for sensing a conductive liquid in a thin material, comprising: (a) a liquid-sensing printed circuit board (PCB), wherein the PCB comprises an electrode assembly having means for detecting a conductive liquid in a thin material based on a change in electrical resistance in the electrode assembly and means for emitting an electronic signal when the liquid is detected; (b) a notification component having means for receiving said signal and means for emitting an alarm when said signal is received; (c) a resilient overmold body partially molded over the PCB such that it covers the means for emitting a signal while leaving the means for detecting a conductive liquid exposed; and (d) a clip for clamping and unclamping the PCB to the thin material and having a proximal area pivotally hinged to the overmold body and a distal area configured to releasably hold the fabric in contact with the electrode assembly and the resilient overmold body. The thin material can be carpet, a garment, fabric, and the like, for example. Said electronic signal can be wireless or be sent through a two-wire cord. Preferably, the overmold body gradually rises up in a distal direction from the proximal area of the PCB to form a knuckle and then steeply descends to a leveled, or substantially so, thin lobe portion. Advantageously, the lobe portion of the overmold body comprises a bump positioned distally and medially on the lobe portion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic view of an exemplary embodiment of a wetness detection device clipped to an undergarment and operably coupled to a notification component. 
         FIG. 2  is a perspective view of an exemplary embodiment of a wetness detection device clipped to an undergarment. 
         FIG. 3A  is a perspective topside view of an exemplary embodiment of a wetness detection device. 
         FIG. 3B  is a perspective underside view of an exemplary embodiment of a wetness detection device. 
         FIG. 4  is a perspective view of an exemplary embodiment of a wetness detection device in an opened position. 
         FIGS. 5A-5B  are perspective views of an exemplary embodiment of a clip, separated from the wetness detection device. 
         FIGS. 6 ,  7 A- 7 B are plan views of an exemplary embodiment of a wetness detection device. 
         FIGS. 8-10  are cross-sectional views of an exemplary embodiment of a wetness detection device. 
         FIG. 11  is a plan view of an exemplary embodiment of a wetness detection device. 
         FIG. 12  is a cross-sectional view of an exemplary embodiment of a wetness detection device. 
         FIG. 13  is a perspective topside view showing a wetness-sensing printed board with the resilient overmold body and clip removed to show the electronic circuitry. 
         FIG. 14  is a plan underside view showing a wetness-sensing printed board with the resilient overmold body and clip removed to show the electronic circuitry. 
         FIG. 15  is a plan topside view showing a wetness-sensing printed board with the resilient overmold body and clip removed to show the electronic circuitry. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the present invention are described below with reference to the above described Figures. It is however, expressly noted that the present invention is not limited to these embodiments, but rather the intention is that modifications that are apparent to the person skilled in the art and equivalents thereof are also included. 
     According to preferred embodiments, the teachings herein are directed to a wetness-detection device  22  having a wetness-sensing printed board  60 , a resilient overmold body  48  partially molded over the printed board  60 , and operably coupled to a clip  30 . More specific embodiments include the proximal end of the clip  30  hinged to the overmold body  48  such that the clip  30  can be moved from an open and closed position, as depicted in  FIGS. 7A-7B . More specifically,  FIG. 4  depicts a clip  30  in an open position, where it can advantageously receive a fabric, such as an undergarment  28 .  FIG. 3A  shows the clip  30  in a closed position unattached to a fabric, while  FIG. 2  depicts the clip  30  in a closed position, clamping an undergarment  28 . Once the undergarment  28  or fabric is positioned into the area  31  between the clip  30  and the printed board  60 , the opened clip  30  can be pressed toward the printed board  60  to a closed position to securely lock the undergarment  28  to the printed board  60  (See  FIG. 2 , for example). When desired, the closed clip  30  can be reopened to release the wetness-detection device  22  from the fabric. 
     The wetness-sensing printed board  60  preferably includes a rigid base layer  62  that includes a top electrode assembly  71   a  and a bottom electrode assembly  71   b  that are each individually configured to detect a conductive liquid in an undergarment  28 , or fabric. Non-rigid substrates can also be used as the base layer  62  in other embodiments. Further, non-preferred embodiments are directed to printed boards  60  only having a top electrode assembly  71   a  or a bottom electrode assembly  71   b , but not both. The top electrode assembly  71   a  includes an electrical circuit preferably having an outer electrode  72  separated by a non-conductive (or weakly conductive) gap  66  from an oppositely charged inner electrode  70 . The top electrode assembly  71   a  also preferably includes a connecting segment  80  that connects one of the top electrodes  70  or  72  to the top connecting wire  27   a.    
     Likewise, the bottom electrode assembly  71   b  also includes a circuit that preferably includes an outer electrode  78  separated by a non-conductive (or weakly conductive) gap  79  from an oppositely charged inner electrode  76 . The bottom electrode assembly  71   b  also preferably includes a connecting segment  82  that connects one of the bottom electrodes  76  or  78  to the bottom connecting wire  27   b . In a preferred embodiment, a plated through hole  64  that traverses through the base layer  62  electronically connects the inside pair of like-charged electrodes  70  and  76  and a solid connector  68  that traverses through the base layer  62  electronically connects the outside pair of like-charged electrodes  72  and  78 . 
     Preferably, the connecting segments  80   82  and connecting wires  27   a    27   b  can be positioned proximally and medially on the printed board  60  such that they are covered by the resilient overmold body  48 . In a preferred embodiment, the printed board  60  also includes a portion having one or more anchor holes  63  for anchoring the resilient overmold body  48  to the wetness-sensing board  60  during overmolding. 
     According to certain embodiments, the pair of oppositely charged electrodes  70   72  of the top electrode assembly  71   a  and the pair of oppositely charged electrodes  76   78  of the bottom electrode assembly  71   b  can define an open circuit (or a weak circuit having high resistance) in their natural state where conductive matter is not present in their respective gaps  66   79 . The high resistance between the electrode pairs  70   72  and  76   78  is detectable by the notification component  24  within the complete wetness detection alarm system  20 . When a conductive liquid, such as urine enters into one or more gaps  66   79 , the electrical resistance between the electrodes  70   72  and/or  76   78  is lowered as the circuit closes or becomes more conductive. This change in lowered resistance from the natural state of the electrode pairs  70   72  and/or  76   78  is quickly communicated to the notification component  24  causing it to emit an alarm. 
     Preferably, the wetness-detection device  22  can be operably coupled to the notification component  24  by a two-wire cord  26  or by wireless means to form a complete wetness detection alarm system  20 . In a preferred embodiment a two-wire cord  26  provides a means for connecting the present invention to a notification component  24 , wherein the two-wire cord  26  divides into a top-connecting wire  27   a  to electronically connect the top electrode assembly  71   a , and into a bottom-connecting wire  27   b  to electronically connect the bottom electrode assembly  71   b . Preferred two-wire cords  26  can be configured to a variety of lengths. For example, the length can be very short such that the notification component  24  is proximal to or integral with the wetness detection device  22 . Alternatively the length of the two-wire cord  26  can be longer such as shown in  FIG. 1 . According to wireless embodiments, the change in resistance can be communicated from the wetness detection device  22  as a wireless signal to the notification component  24  that includes means for receiving the wireless signal and means for emitting an alarm based on said signal. 
     Upon activation, the notification component  24  is preferably configured to emit any type of suitable alarm. Preferred alarms can be visual, audible, vibrating, or a wireless signal emitted to another remote device, or a combination thereof. Preferred notification components  24  can contain their own power source, such as a battery, and are configured to quickly detect a change in resistance in the wetness detection device  22  and to quickly emit a sufficient alarm based on the change in resistance. A sufficient alarm generally relates to one that is activated near the start of accidental urination, such that the wearer will quickly wake up and finish urinating in a toilet, instead of in their undergarment or clothing. Accordingly the teachings herein are of great advantage to those suffering incontinence or enuresis. Preferred notification components  24  are readily known in the art, such as those disclosed in U.S. patent application Ser. No. 10/950,795, Publication No. US 2005/0110644 A1, filed Sep. 27, 2004 which is expressly incorporated by reference in its entirety. Preferred wetness detection devices  22  are configured to work compatibly with said notification components  24 , and other suitable devices. 
     The resilient overmold body  48  preferably covers: the proximal end and the middle of the printed board  60 , the connecting wires  27   a    27   b , anchor holes  63 , and the connecting segments  80   82  of the top and bottom electrode assemblies  71   a    71   b . Preferably, the resilient overmold body  48  gradually rises up in a distal direction from the proximal area of the printed board  60  to form a knuckle  46   a  and then steeply descends to a leveled, or substantially so, thin lobe portion  44 . Advantageously the knuckle  46   a  is configured to allow the clip  30  to hinge to it. The knuckle  46   a  covers: a proximal area of the printed board  60 , one or more anchor holes  63 , and a portion of the connecting segment  80 . Preferably, the lobe portion  44  covers: a middle area of the printed board  60 , and one or more anchor holes  63  and the remainder of the connecting segment  80 . Advantageously, the overmold body  48  does not cover the inner and outer oppositely charged electrodes  70  and  72  or the gap  66  that separates them. 
     The lobe portion  44  preferably includes a distal medial bump  50  in the form of a quarter-ellipsoid that gradually slopes upward and distally from the middle of the lobe portion  44  and steeply descends at the distal end of the lobe portion  44 . This preferred bump  50  allows for differential biasing, or clamping of the undergarment against the clip&#39;s teeth  32 . Alternative shapes (e.g., quarter-spherical, rectangular, triangular), numbers (e.g., 2, 3, 4), sizes, and position of bumps (e.g., off-center, near the periphery of the lobe portion  44 ) can vary in other embodiments. Preferably when the clip  30  is in the closed position there is a small space  31  between lobe portion  44  and the underside of the clip  30  and the distal medial bump  50  and the underside of the clip  30 . This space is  31  is configured to receive fabric or an undergarment  28 . When clamped to an undergarment  28 , the clip  30  is configured to hold the undergarment  28  against the top electrode assembly  71   a  and the lobe portion  44  and the distal medial bump  50 , as shown in  FIG. 2 . 
     Preferably, the resilient overmold body  48  forms a thin underside layer  45  over a proximal and middle area of the printed board  60  and covers: one or more anchor holes  63  and the connecting segment  82 . Advantageously, the underside layer  45  does not cover the inner and outer oppositely charged electrodes  76  and  78  or the gap  79  that separates them. 
     In an exemplary embodiment of the present invention, the clip  30  includes a proximal area configured to hinge to the resilient overmold body  48 , more preferably the clip  30  is configured to hinge to the knuckle  46   a . Advantageously, the clip&#39;s proximal end can include a pair of pin guides  39   a  and  39   b  that are configured to straddle the knuckle  46   a.    
     The pin guides  39   a    39   b  individually include a pivot pin hole  43  configured to allow a pivot pin  40  to traverse through. Preferably, the hinge knuckle  46   a  includes an interior pin opening  47  that aligns with the pivot pin holes  43  when the pin guides  39   a  and  39   b  straddles the hinge knuckle  46   a  and define a hinge axis  42 . Under this preferred configuration, the pivot pin  40  acts as a hinge for the clip  30  and the overmold body  48 . In a more specific embodiment of the hinging mechanism, a portion of the knuckle  46   a  can define end-openings for the pivot pin  43  that have a greater diameter than an interior pin opening  47 . 
     Preferably, the pin guides  39   a    39   b  can individually include heels  38   a    38   b  to give the clip  30  over-center action to set a spring force in the hinge knuckle  46   a  to snap and hold the clip  30  shut as the heels  38   a    38   b  goes past center when the clip  30  is moved toward a closed position. More specifically when the clip  30  is an open position at a ninety degree angle to the base layer  62  and is moved toward the base layer  62 , the spring mechanism will cause the clip  30  to snap shut when it is past forty-five degrees, or substantially so. (See  FIG. 7   a ) However, other hinging and spring mechanisms could be employed and other means for generating a clamping force to hold the clip  30  into the closed position could be employed. 
     According to further embodiments, the distal area of the clip  30  includes a protruding gripping surface  37  where the face of the gripping surface  37  is parallel with the printed board  60  when the clip  30  is in the closed position. When the clip  30  is in the open position as shown in  FIG. 4 , the face of the gripping surface is preferably perpendicular to the printed board  60 . It is preferred that the gripping surface  37  is planar, or substantially so, but other embodiments can include a textured or angled gripping surface. In a preferred embodiment, the gripping surface  37  is configured to contact the top electrodes  70   72  when the clip is in a closed position and unattached to a piece of fabric or undergarment  28  as shown in  FIG. 6 . The top electrode assembly  71   a  acts as a sensing strike plate in this embodiment. When a fabric or an undergarment  28  is clamped down by the clip  30 , the gripping surface  37  is configured to hold the fabric or undergarment  28  against the top electrode assembly  71   a.    
     The distal area of the clip  30  preferably includes one or more retention teeth  32 . More specifically, the gripping surface  37  can include a row of retruded teeth  32 . In further embodiments, the teeth  32  are retruded such that they are parallel to the printed board  60  and point toward the resilient overmold body  48  as shown in  FIG. 3A  and  FIGS. 6-7B  when the clip  30  is in the closed position and unattached to fabric or an undergarment  28 . In this position there is preferably a small space between the end of teeth  32  and the one or more bumps  50 . Additionally, when the clip  30  is in an open position ( FIG. 4 ) the teeth  32  are preferably configured to be perpendicular with the printed board  60  such that they point downward towards the printed board  60  and the overmold body  48 . 
     More specifically, the teeth  32  can be configured to engage the undergarment  28  or fabric against the resilient overmold body  48 , and even more preferably against the lobe portion  44  and the one or more bumps  50 . The combination of the gripping surface&#39;s  37  clamping force and the grabbing effect of the teeth  32  make it very difficult for the fabric or undergarment  28  to accidentally disengage with the wetness detection device  22 . The retruded configuration of the teeth  32  also add a safety feature in that it makes it very difficult for the pointy tips to puncture or hurt the wearer. 
     The distal end of the clip  30  preferably includes a release notch  36  where a person can insert their finger to lift the clip  30  from the closed position to an open position. The release notch is preferably a concave crescent shape notched into the gripping surface  37 , but can be other suitable shapes. 
     While preferred embodiments herein are directed to fastening a wetness detection device  22  to an undergarment  28 , those with skill in the art will recognize that the clips  30  described herein can be attached to any other suitable fabric, or thin material for detection of any conductive liquid. For example, the wetness detection devices  22  described herein can be used to attach to carpets, rugs, or carpet pads in an area susceptible to flooding, such as a basement, for example. Additionally, the wetness detection devices  22  described herein can be used to attach to plastic sheeting in a crawl space, for example. 
     Additionally, the clips  30  and overmold bodies  48  described herein can be used without a printed board  60 , and can be simply used to attach light-weight items to clothing or other materials against a base layer  62  (rigid or non-rigid). Accordingly a rigid base layer  62  alone can be substituted for a printed board  60  in the embodiments described above. According to these embodiments, the clips  30  can be used to fasten a name tag to a user&#39;s shirt or to tether emergency stop keys for personal watercraft (e.g., WAVERUNNER® and JET SKI® brands) and exercise machines (e.g., treadmills and stepping machines) to the user. 
     The invention may be embodied in other specific forms besides and beyond those described herein. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting, and the scope of the invention is defined and limited only by the appended claims and their equivalents, rather than by the foregoing description.