Patent Description:
Incontinence can arise for many reasons and at any age. Physical trauma and any number of medical conditions can give rise to incontinence. Incontinence can also be a product of age, such as when a man's prostate becomes enlarged, surgery effects the nerves serving the bladder, or the man develops Alzheimer's disease or dementia. Incontinence may present, e.g., by the sporadic or continual trickling of urine from the penis or may result in spontaneous release of the entire contents of the bladder.

As disclosed in <CIT>, a hygienic article for a male may take the form of a tube having an open end adapted to receive a limp penis and a closed second end, the tube including an absorbent material extending at least within the second end of the tube and being adapted to absorb fluids.

<CIT> discloses a leakage-free absorbent pad for men. The pad comprises a liquid permeable top sheet, a back sheet, an absorbent member arranged between both sheets, and a pair of liquid impermeable gather sheets facing each other on the top sheet.

<CIT> discloses a disposable men's diaper. The diaper comprises a liquid permeable top sheet, a liquid impermeable back sheet, and a liquid absorbent body disposed therebetween. The two sheets provided are covered so that a space is formed between the sheet and the back sheet, and a superposition part opened along the longitudinal direction of the diaper body is provided.

<CIT> discloses a disposable absorbent device for male wearers. The device comprises an outside layer and an absorbent batt wherein the part of said outside layer situated next to the wearer's body is provided with an opening preferably of a long and narrow shape equipped with elastics, to fit and surround the users penis and/or penis and scrotum.

<CIT> discloses a hygienic article for a male. The article comprises a water resistant tube, and an absorbent material disposed within a portion of the interior of the tube configured to absorb urine, wherein the second end is configured to provide radial support to the tube to reduce axial force tending to remove the hygienic article from the penis.

The present disclosure provides a hygienic article for a male configured to fit and to secure to a wide range of sizes and configurations of a male penis and to adjust to variations in size and shape of a male penis during use, while conforming to the overall anatomical configuration of a user to be, e.g., practically indistinguishable under a user's clothing.

The article according to the principles of the present disclosure includes elasticized side-panels which mechanically couple distal ends of a main chassis of the article to define a pouch in the article. The elasticized side-panels are configured, in some embodiments, with a varying overall elasticity between proximal and distal attachment points of the elasticized panels to the chassis. For example, elastic threads in the elasticized side-panels may vary in size, amount, and elasticity. The variations in the elastic threads may be configured, e.g., to provide a center portion of the elasticized side-panels between the proximal and distal ends with relatively greater elasticity and, thus, relatively relaxed elasticity at the proximal and distal attachment points of the side-panels to the chassis. According to the principles of the present disclosure, the structure of the elasticized side-panels and assembly thereof as a part of the article provides a desired lateral compression towards securing the article to a user while further providing self-adjustment to accommodate and conform to localized variation in anatomical configuration, e.g. a changing size and shape of a male penis of a user during use of the article.

The hygienic article further secures to a user at the penis with a fastening component. A fastening component according to the principles of the present disclosure may be in the form of one of a strap, beading, band, strip, clamps, and belt, by way of non-limiting examples. In an example with the fastening component with a form such as a strap, the strap is configured with ends emanating from a posterior portion of the chassis of the article and includes hook material portions to engage a landing zone on the exterior of the chassis of the article, the landing zone including one or more materials varying from the chassis to provide secure attachment to the fastening strap. The strap also includes an additional landing zone on the strap itself to allow for the strap to secure to itself in an overlapping configuration. The fastening strap further includes elastic material to provide additional flexibility, with one or both of lateral and longitudinal stretch capabilities, in performance and adjustment.

A hygienic article according to the principles of the present disclosure is structured to inhibit soiling of clothing from intermittent or sporadic leakage of urine from a penis over time by containing and absorbing the leakage - while providing secure and dynamically variable fit, unobtrusive appearance, preventing pooling of liquid against the skin, providing airflow to the skin. With a minimized footprint, an article according to this disclosure thereby minimizes exposure of anatomy to pooling of fluid. In some embodiments, an article according to this disclosure is as little as one eighth of the surface area of conventional male incontinence guard or shield products, and as little as one quarter of the size of other male incontinence guard products used only over a penis. The size and anatomically conforming characteristics of an article according to this disclosure result in no substantial impact on the appearance of a clothed user.

A hygienic article according to this disclosure is targeted to contain leakage from the male anatomy over time, such as, by way of example only, stress or urge leakage or post-voiding incontinence, as opposed to substantial or complete emptying of the bladder in a single event or short amount of time. To provide capacity for numerous such events over time, all while minimizing footprint, an article according to this disclosure employs a relatively high density absorbent component in a structure which directs fluid away from the skin to the absorbent core. This structure of the present disclosure includes the securing of the chassis of the article while providing variable elasticity in side panels thereof, by which the article conforms and maintains the path to the absorbent core as the size and position of the male anatomy changes during use. The fluid and absorbent core are contained between a water barrier back sheet and a one-way moisture barrier (acquisition distribution layer). The article can contain sporadic, relative small amounts of liquid to accommodate the absorption rate of a high density material, with the high density absorbing material in turn providing capacity to absorb numerous leakages.

Referring to <FIG> and <FIG>, a hygienic article <NUM> according to the principles of the present disclosure includes a chassis <NUM> with a non-woven outer layer <NUM>. In this exemplary folded configuration, chassis <NUM> has a front side <NUM> and a back side <NUM>.

The hygienic article <NUM> includes a fastening strap <NUM> fixed to the chassis <NUM> at the back side <NUM>. Fastening strap <NUM> is fixed to the chassis <NUM> at a central portion of the fastening strap <NUM>. The inner surface <NUM> of the fastening strap <NUM> interfaces with the back side <NUM> of chassis <NUM>, and the outer surface <NUM> of the fastening strap <NUM> is opposite the inner surface <NUM>. Fastening strap <NUM> includes pull tabs <NUM>, i.e. finger-lifts, at opposing distal ends thereof and attachment material <NUM> on the inner surface <NUM> and proximate each of the pull tabs <NUM>. Attachment material <NUM> is complementary to the non-woven outer layer <NUM> in that these materials releasably secure to each other. By example, the attachment material <NUM> may include a hook material, and the outer layer <NUM> may include a loop material with which the hook material can engage and releasably secure, allowing for multiple occurrences of removing and re-securing the article to the penis.

With particular reference to <FIG>, fastening strap <NUM> is secured to the chassis <NUM> across an attachment interface <NUM> between the chassis <NUM> and a central portion of the fastening strap <NUM>. The central portion of the fastening strap <NUM> and distal portions of the fastening strap <NUM> include non-woven material. Between the non-woven material portions <NUM>, fastening strap <NUM> includes elastic portions <NUM>. In the exemplary embodiment illustrated in, e.g., <FIG>, the fastening strap <NUM> has two elastic material portions <NUM> alternating between three non-woven material portions <NUM>. It should be understood that other configurations of variable elasticity between central and distal portions of a fastening strap <NUM> are within the scope of the present disclosure.

In some embodiments of the present disclosure, attachment interface <NUM> extends substantially across the back side <NUM> of the chassis <NUM>, and fastening strap <NUM> extends substantially equally from the back side <NUM>. In such embodiments, tensile forces applied to the fastening strap <NUM> are born by the fastening strap <NUM> and are not transferred to a localized portion of the back side <NUM> of the chassis <NUM>. Such a configuration provides stability and comfort to a user, by maintaining the position of the chassis <NUM> against the anatomy, while allowing the elastic material portions <NUM> of the fastening strap <NUM> and the elasticized side panels <NUM> of the chassis <NUM> to accommodate, e.g., changes in size and position of the anatomy and position of the user. Such a configuration also facilitates use of the hygienic article <NUM> by having equal portions of the fastening strap <NUM> on both sides of the hygienic article <NUM>, which allows for securing of the article <NUM> without twisting and use of either hand as dominant.

The front side <NUM> of the chassis <NUM> provides a landing zone for the attachment material portions <NUM> of the fastening strap <NUM>. In some embodiments, the fastening strap <NUM> may, in part, engage with itself - e.g. the non-woven material portions <NUM> on the outer surface <NUM> of the fastening strap <NUM> may also be complementary to the attachment material <NUM> and, thereby, further define a landing zone for the other end of the fastening strap <NUM>.

In a folded configuration such as <FIG>, and <FIG>, chassis component <NUM> is folded over approximately halfway along the length thereof, with front corners <NUM> brought adjacent to back corners <NUM>, with the non-woven outer layer <NUM> on the exterior, defining the front side <NUM> and the back side <NUM> of the chassis <NUM>.

With further reference to <FIG>, the hygienic article <NUM> includes two elasticized side panels <NUM>. According to the principles of the present disclosure, the elasticized side-panels <NUM> provide radially inward forces against the anatomy of a user in the pouch <NUM> of the article <NUM>. These forces contribute to securing article <NUM> to the user, while the elasticity allows article <NUM> to conform the article <NUM> to the anatomy of the user during use.

Side panels <NUM> include breathable, hydrophobic material. As illustrated in the example of <FIG>, with the chassis <NUM> in an unfolded configuration, side panels <NUM> extend the length of chassis <NUM> between front corners <NUM> and back corners <NUM>. Each of side panels <NUM> extends over substantially half of the surface of the unfolded chassis <NUM> and are each continuously coupled about the perimeter of chassis <NUM> on the three exterior sides thereof that overlap the perimeter of chassis <NUM>. In some embodiments, side panels <NUM> are integral with the non-woven outer layer <NUM> and are secured to the chassis at distal ends <NUM> and <NUM>, respectively, with, e.g., adhesive, ultrasonic bonds, pressure welds, or heat bonds. Side panels <NUM> are not engaged with each other at the midpoint of the chassis <NUM> along the length of the chassis <NUM>. Each of the side panels <NUM> may include varied numbers of elastic threads <NUM> configured to pull the chassis <NUM> into a folded configuration with the respective front corners <NUM> and back corners <NUM> toward each other. With particular reference to the example illustrated in <FIG>, according to the principles of the present disclosure, when the chassis <NUM> is folded, the side panels <NUM> define an opening to a pouch <NUM> defined between the interior surfaces of the side panels <NUM> and the chassis <NUM>.

In some embodiments of the present disclosure, the outer layer <NUM> and the elasticized side-panels <NUM> are formed from a single sheet <NUM>. As illustrated in the example of <FIG>, such sheet <NUM> may be configured to be initially approximately three times the width of the main chassis <NUM>. The side panels <NUM> are defined from the sheet <NUM> by laterally folding the portions of sheet <NUM> outside of the chassis <NUM> in half at folds <NUM>. In such embodiments, the side panels are two layers of the material of sheet <NUM>, each half the width of the chassis <NUM>, while the outer layer <NUM> of the chassis <NUM> is a single layer of the same sheet <NUM>. With further reference to <FIG>, the distal ends <NUM>, <NUM> of the side panels <NUM> are secured to the chassis <NUM> with, e.g., adhesive. Thereby, the elasticized side panels <NUM> define a one-piece tubular shape defining a pouch therein to encapsulate the male anatomy. In some embodiments, the height of the side-panels is <NUM>-<NUM> and are variable depending upon the size change and specific fit needed for a user and the sizing of the other components of the article <NUM>.

Side panels <NUM> include one or more elastic threads <NUM>. As illustrated in the example in the Figures, side panels <NUM> each include three of elastic threads <NUM>. In other embodiments of the elasticized side-panels <NUM>, three to twelve elastic threads are used per side, strategically spaced for optimal gathering capability and encapsulated between layers of the sheet <NUM>. In such embodiments, the threads are between <NUM> and <NUM> long and are spaced between <NUM> and <NUM> apart. These dimensions are variable to match the required size and fit and to correspond to the other components of the article.

The elastic threads <NUM> may be configured to provide variable elasticity, such as providing a center portion of the elasticized side-panels <NUM> between the distal ends <NUM>, <NUM> with relatively greater elasticity and, thus, relatively relaxed elasticity at the ends <NUM>, <NUM>. According to the principles of the present disclosure, the elastic threads <NUM> may provide variable elasticity by varying the stretch factor applied to the threads <NUM> while the threads <NUM> are being affixed to the side panels <NUM>. In some embodiments, different ones of the elastic threads <NUM> in a single side panel may be configured with varying stretch factor profiles.

In embodiments where the center portion of the side panels <NUM> has greater elasticity, the configuration facilitates use of the article <NUM>, conformity to the penis, a secure fit to the penis and comfort during use. With the structure of the article <NUM> gathering the side panels <NUM> in the central portion thereof as the front corners <NUM> and back corners <NUM> are brought together, the pouch <NUM> is defined. Being gathered at the center, the elastic side panels <NUM> can accommodate variation in anatomy and positioning from front to back or back to front. Being elastic, the side panels <NUM> can engage around the male anatomy prior to being overlapped with the fastening strap <NUM>, thereby allowing the compressive forces of the fastening strap <NUM> to also be applied to the side panels <NUM>.

In some embodiments, the layers of the side panels <NUM> are secured with adhesive, ultrasonic bonds, pressure welds, or heat bonds at discrete locations along the length of the elastic threads <NUM> according to desired gathering properties of the non-woven material and, thereby, to provide the fit and function of the hygienic article <NUM> according to the principles of the present disclosure. In some embodiments, elastic snap back of the threads <NUM> is approximately <NUM> to <NUM> inch to localize gathering of the side-panels <NUM> at a center portion thereof. This distance is variable according to the desired size and fit and to correspond with the size of the other components of the hygienic article <NUM>. The variable elasticity of the elasticized threads <NUM> in the side panels <NUM> allows the article <NUM> to accommodate variable changes in the shape and size of the penis, which may occur continually during use of the article <NUM>.

In some exemplary embodiments, elastic threads <NUM> for the elasticized side-panels <NUM> may have a size of <NUM> decitex, and the threads <NUM> may be used at a stretch factor of between <NUM> to <NUM> times their relaxed length. It should be understood that the size of the threads <NUM> and the stretch factor applied to the threads <NUM> are variable according to the desired range of elasticity sought, size, and fit and to correspond with the size of the other components of the hygienic article <NUM>. For example, the threads <NUM> can be in the range of <NUM>-<NUM> decitex.

Referring to <FIG>, <FIG>, and <FIG>, the fastening strap <NUM> is secured to the back side <NUM> of the main chassis. When folded over and secured to the penis with the fastening strap <NUM> secured, the distal ends of the article <NUM> extend superiorly above the location of the fastening strap <NUM>. This structure provides a consistent engagement between the user, the side panels <NUM>, and the inner surface of the chassis <NUM>. This structure also provides a path for air flow between the strap and the user through the breathable fabrics of the article <NUM>, which further promotes comfort and simultaneously provides inhibition of skin irritation and skin deterioration by virtue of the enhanced air flow.

With the fastening strap <NUM> securing the article <NUM> to a user, the article <NUM> provides a secure and comfortable fit and accommodation of variable changes in penis size and position. With the elasticized components <NUM> of the fastening strap <NUM> providing compressive force to secure the chassis <NUM> to the anatomy, changes in size and position of the penis are accommodated and the penis is kept within the elasticized side panels <NUM> - as opposed to the chassis shifting back and forth across a user between the pair of side panels <NUM>. With the fastening strap <NUM> including elastic portions <NUM> overlapping the side panels <NUM>, the strap <NUM> both anchors the chassis <NUM> and allows for the expansion of the side panels <NUM>.

As illustrated in <FIG>, the chassis <NUM> of hygienic article <NUM> includes a plurality of layers. In the example of the Figures, the chassis <NUM> includes a non-woven, air permeable, moisture barrier back sheet <NUM> directly engaged with the portion of sheet <NUM> defining outer layer <NUM>, the engagement being provided, in some embodiments, an adhesive layer <NUM>. In such embodiments, the outer layer <NUM> of the chassis <NUM>, as a soft outermost covering of the article <NUM>, inhibits noise from the article <NUM> from adjustment or contact with clothing during movement of a user.

Adhered to the back sheet <NUM> on the inward side thereof is an absorbent core component <NUM>, the core component extending across a smaller area of the chassis <NUM> than the back sheet <NUM>. An acquisition distribution layer <NUM>, being substantially equal to the core component <NUM> in the area of the footprint over the chassis <NUM>, is layered on the core component <NUM> opposite the back sheet <NUM>. A top sheet <NUM> overlaps the core component <NUM> and acquisition distribution layer <NUM>. The top sheet <NUM> directly interfaces with the back sheet <NUM>, and the top and back sheets <NUM>, <NUM> are fixed with a window of adhesive that extends about and surrounds the core component <NUM> and the acquisition distribution layer <NUM>. The top sheet <NUM> overlaps all edges of the back sheet <NUM>, and, thus, the top sheet <NUM> and the side panels <NUM> define the pouch <NUM> therebetween and are the only components of the article <NUM> that may directly contact a user within the pouch <NUM>.

In some embodiments, the core component <NUM> is fixed to the back sheet with adhesive. For example, the adhesive may be in the configuration of a narrow lengthwise strip <NUM> in the center of the chassis, to leave free as much of the surface area of the absorbent core component <NUM> as possible to receive and contain liquid. The core component <NUM> is selected to provide absorption of sporadic, partial leakage of bladder contents over time; in some embodiments, the article <NUM> provides substantially <NUM> ounces of liquid absorption capacity over time. To minimize the size and appearance of the article <NUM> while maximizing capacity, and because the article <NUM> is designed to support partial leakage over time, the core component <NUM> has a relatively high density as compared to conventional, larger incontinence articles. The size of the core component <NUM> and, in general, the article <NUM>, not only minimizes the effect, if any, on the natural appearance undergarments of a user, but the contained size with substantially exposed surface area prevents pooling of leakage and the attendant discomfort and irritation of skin.

The non-woven back sheet <NUM> is an air permeable, moisture barrier material which functions to contain liquid drawn to the core component <NUM> within the article <NUM>. With this structure, the article provides for airflow therein to, e.g., cool the contact area between the article and the user. By way of non-limiting example, the moisture barrier may include a poly-film material. In addition to or as an alternative to adhesive, the back sheet <NUM> may be, in some embodiments, secured to the core component by one of ultrasonic bonding, pressure welding, and heat bonding. In some embodiments in which the non-woven back sheet <NUM> is secured with adhesive, the adhesive is configured in a pattern, e.g. a dot matrix, the pattern being complementary to the configuration of one or both of the core component <NUM> and the non-woven back sheet <NUM>, the pattern being complementary so as to secure the back sheet <NUM> while maximizing the absorption performance of the core component and minimizing the impediments to fluid flow in the article <NUM>.

The absorbent core component <NUM>, in some embodiments, includes a material made with absorbent polymers encapsulated within hydro-bonded cellulose sheets to provide maximum absorption with minimal thickness. Various levels of absorption can be achieved by different grades and patch sizes of such materials, e.g. from <NUM> fluid ounce to <NUM> fluid ounces. In some embodiments, the core component <NUM> is tenderized to make the article <NUM> more pliable and, thus, comfortable to a user. In some embodiments, width of the core component is <NUM> to <NUM>, and length is up to <NUM>. In accordance with the principles of the present disclosure, the dimensions of the core component may be varied to achieve desired absorption properties.

The acquisition distribution layer <NUM> is, in some embodiments, fixed to the core component <NUM> with a thin layer of adhesive <NUM>. The thin layer of adhesive <NUM> avoids clogging of the through passages of the layer <NUM>. The acquisition distribution layer <NUM> is a one-way moisture barrier material oriented to allow flow of liquid therethrough only to the core component but not from it; it allows fluid to pass through into the absorbent core component <NUM> and prevents backward flow of fluid by way of conical-shaped flow holes having a smaller end closest to and at the core component <NUM>. In accordance with the principles of the present disclosure, this feature protects the comfort of the wearer by reducing the possible leaking of urine and soiling the clothing. In some embodiments of the article of the present disclosure, the one-way moisture barrier component <NUM> has a width of <NUM> to <NUM> and a length of <NUM>, which is variable in accordance with the size of the absorbent core component <NUM>. In addition to or as an alternative to adhesive, the one-way moisture barrier component <NUM> may be secured to the core component by, e.g., one of ultrasonic bonding, pressure welding, and heat bonding, with the pattern of secured engagement of those components being of a design to not restrict the flow of urine or the one-way barrier characteristics of the conical shaped flow holes.

The hygienic article of the present disclosure includes a top sheet <NUM> interior and superior to the one-way moisture barrier <NUM>. The top sheet <NUM> defines an inner surface of a pouch <NUM> of the article for direct contact with a user. The top sheet <NUM> may have an ultra-soft fiber configuration to provide a user comfort. The top sheet <NUM> is affixed to the back sheet <NUM> with a perimeter seal of adhesive within the footprint of the chassis <NUM>, with the core component <NUM> and acquisition distribution layer <NUM> between the top and back sheets <NUM>, <NUM>. In some embodiments, the top and back sheets <NUM>, <NUM> may be adhered with ultrasonic bonds, pressure welds, or heat bonds. The amount of adhesive, ultrasonic bonds, pressure welds, or heat bonds is limited to avoid rough or hard spots in the chassis <NUM> from the bond of the components that would irritate the skin of a user.

In some embodiments of the article of the present disclosure, the dimensions of the top sheet <NUM> are <NUM> wide by <NUM> long, which are variable in correspondence with the other components and to create different levels of size, fit, and absorption. The top sheet <NUM> material includes the properties of extreme softness and hydrophilic passages to allow urine to flow through unrestricted to the one-way moisture barrier component <NUM> and, in turn, into the absorbent core component <NUM>. The assembly of the back sheet <NUM>, absorbent core component <NUM>, one-way moisture barrier component <NUM>, and top sheet <NUM> comprises a chassis <NUM> of the article.

In some embodiments, the size of the fastening strap <NUM> is <NUM> long and between <NUM> and <NUM> wide, which dimensions are variable according to the desired size and fit and to correspond with the size of the other components of the hygienic article <NUM>. In some embodiments according to the principles of the present disclosure, the fastening component may be in the form of a beading, band, strip, clamp, or belt to secure the hygienic article <NUM> to a user's anatomy while providing flexibility in performance and in adjustment of the fit of the article to the user. In some embodiments, the fastening component may be in the form of a beading of a skin-friendly silicone material. In some embodiments, the fastening component may include adjustable, pliable bands or band-strips. In some embodiments, the fastening component may include elasticized clamps that wrap around the proximal end of the article. In some embodiments, the fastening component is in the form of a reusable, relatively wire-like belt that is attached on the posterior center of the back of the chassis <NUM> and capable of being bent around the chassis <NUM> once the chassis <NUM> is in place on a user.

Claim 1:
A hygienic article (<NUM>) for a male comprising:
an elongated chassis component (<NUM>) including a moisture barrier back sheet (<NUM>), an absorbent core component (<NUM>), a one-way moisture barrier component (<NUM>) coupled to the absorbent core component, and a top sheet (<NUM>) overlapping the absorbent core component (<NUM>) and the one-way moisture barrier component (<NUM>), the top sheet (<NUM>) and the back sheet (<NUM>) having a continuous engagement surrounding the absorbent core component (<NUM>) and the one-way moisture barrier component (<NUM>);
elasticized side-panels (<NUM>) extending from longitudinal sides of the chassis component (<NUM>), the side-panels having exterior corners (<NUM>,<NUM>) folded over the chassis component (<NUM>) to a lateral midpoint of the chassis component and coupled to the top sheet (<NUM>) at opposing ends of the chassis component, the side-panels (<NUM>) drawing the opposing ends of the chassis component to each other at a relaxed configuration of the side-panels, the side-panels and top sheet defining a pouch (<NUM>) therebetween when the chassis component is folded, the pouch being configured to receive a penis therein with the side-panels in a stretched configuration, the article being configured to engage and conform to the penis upon the side panels being relaxed from the stretched configuration; and
a fastening strap (<NUM>) coupled to an exterior surface of the chassis component (<NUM>), the fastening strap including an elastic material and hook material portions, the hook material portions configured to releasably secure to the exterior surface of the chassis component with the elastic material of the fastening strap in a stretched configuration to secure the hygiene article to the penis.