CA2180789C - Post formed curved tampon assembly - Google Patents
Post formed curved tampon assembly Download PDFInfo
- Publication number
- CA2180789C CA2180789C CA002180789A CA2180789A CA2180789C CA 2180789 C CA2180789 C CA 2180789C CA 002180789 A CA002180789 A CA 002180789A CA 2180789 A CA2180789 A CA 2180789A CA 2180789 C CA2180789 C CA 2180789C
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- CA
- Canada
- Prior art keywords
- tampon assembly
- fingergrip
- mold
- tampon
- post forming
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/02—Bending or folding
- B29C53/08—Bending or folding of tubes or other profiled members
- B29C53/083—Bending or folding of tubes or other profiled members bending longitudinally, i.e. modifying the curvature of the tube axis
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/20—Tampons, e.g. catamenial tampons; Accessories therefor
- A61F13/2082—Apparatus or processes of manufacturing
- A61F13/2085—Catamenial tampons
Abstract
There is provided a method for post forming an assembled tampon assembly into a curved tampon assembly. Before employing this method, the tampon assembly is completely formed using existing manufacturing methods into a typical straight axial oriented tampon assembly. The tampon assembly is then heated to permit flexing and reorientation of the axis of one or more portions of the tampon assembly. Next, the heated tampon assembly is positioned in a mold cavity of a cold forming mold. The inner surface of one or more portions of the mold cavity has a desired arcuate shape or axial orientation in order to obtain a desired predetermined radius of curvature. Thereafter, the tampon assembly is held in the mold until the various components of the tampon assembly cool down. Finally, the cooled tampon assembly is removed from the mold and is ready to be packaged for distribution.
Description
2180789 , POST FORMED CURV15D TAMPON A~.~F.MRl.Y
BACKGROUND O~7 TIIE INVE;NTION
I. Field of the Invention The present invention relates generally to tampon assemblies including an applicator and a 5 pledget for vaginal insertion of tampon pledgets. More particularly, the present invention relates to a method for post forming a plastic-type tampon assembly into a curvcd axial orientation but aRer tl~e initial formation and assembly of the hmpon assembly ---r ' into a normal, straight-formed hmpon assembly.
II. Description of the Prior Art o Generally, methods for forming curved-type tampons pledgets are known. For example, U.S. Patent No. 5,153,971 to T.P. Van Iten, which issued on October 13, 1992, and related U.S.
Patent No. 5,350,371 to also T.P. Van Iten, which issued on September 27, 1994, provide a method for forming a curved hmpon pledget. The pledget is constructed having two dif`erent zones of fiber density and inserted into a mold cavity having two open ends. Then, the pledget is ~ . ~D~i~ at both open ends and, optionally, heated about its periphery within the mold cavity.
Next, the pledget exits the mold cavity having a straight form but quickly blossoms into a curved shaped pledget due to the differing expansion properties of its two ~ones of fiber density.
I
,-- . 2~8078g Thereafter, the pledget may be positioned within a curved tampon applicator to complete assembly of the tampon assembly.
In addition to curved-type tampon pledgets, methods for forming curved plashc tampon applicators for inserting pledgets are also known. Such tampon applicators are typically s ~ ~1 using curved plastic UUIIII. ', such as a barrels and plungers, that are molded or extruded in a ~ ' ' curved ~ - and then assembled with the pledget to proYide tl~e fnished curved tampon applicator product. For example, U.S. Patent No. 5,158,535 to S.C.
Paul, et al., which issued on October 27, 1992, and U.S. Patent No. 5,267,953 to also S.C. Paul, et al., which issued on December 7, 1993 and is a divisional based on the U.S. Patent No.
5,158,535,provideamethodforforiningabarrelandplungerofacurvedtamponapplicatorby injection molding or extrusion. The straight barrel and plunger are individually heat set into an arcuate axial orientation. The barrel has a degree of axial curvature that is greater than that of its original shape. Then, the plunger is inserted into one end of the barrel and, thereafter, a tampon pledget is assembled within the other end of the barrel to complete the formation of the tampon assembly.
The above patents describe processes for forming curved, . such as the pledget, barrel and plunger, that are " 'J, assembled together. Such assembly . ' production and is more difficult since . ' ", sorting and orienting such curved ~ .
requires special attention and expensive assembly machinery. In addition, the formation through 20 the use of curved molds is more difficult than - ' straight cu~ u~
21807g9 Therefore, there is a necd for a new and improved method for permitting tampon --r ' to be IllailuL~,tu~ as existing straight cy.indrica~ t` and assembled using pr~t " ' ' high speed assembly methods while, ~, .1.,~7.~.. - ' 1~, reforming or reorienting the complete tampon assembly into a curved ~ fi~ without further ~ ' v or assembly 5 of 4" ~ t`i SUMMARY OF TlIE INVENTION
Against the foregoing ~al~L~ 1, it is a prima.-y object of the present invention to provide a method of post forming a cu.. . ~ h,ll~, axially straight, plastic-type tampon assembly into an axially curved t.-.mpon assembly.
o It is another object of the present invention to provide such a method for post forming into a curved tampon assembly that is ef.icient and æ
It is a furt.L.er object of tlle present invention to provide such a method for post forming into a curved tampon assembly that permits existing high speed equipment to be used to cllli~i~.lUit; and assemble the ., ~ of the tampon assembly thereby eliminating the need for curved cavity injection molds, plastic I ' ' ~, and orienting equipment, and new or modified assemb.ing machines for curved: .
To accomplish the foregoing objects and advantages, the present invention, in brief summary, comprises the following steps: heating a portion of the formed tampon assembly to a ' elevated ~ .dlUlC, to permit the portion to flex and thereby reorient the axis of the portion. The portion of the tampon assembly is then positioned in a mold cavity that has a 5 Inng " ~ arcuate shape or bend having a desired, 1,.. . ~ radius of curvature such that the positioning of the portion of the tampon assembly in the mold cavity causes the portion to initially adapt to the arcuate orientation of the mold cavity. Thereafter, the portion of the tampon assembly is held in the mold cavity until the tampon assembly cools to a ~..cl' ' reduced . alulc . Lastly, the portion of the tampon assembly is removed from the mold cavity.
o For another; S~ ' . t, the present invention comprises the 6110wing steps: heating a formed tampon assembly that includes a tampon pledget and a tampon applicator to a ,t~ ' elevated i . ~, to permit the tampon assembly to flex and thereby reorient tlle axis of the tampon assembly. The tampon assembly is then positioned in a mold cavity that has a ~ " ' arcuate shape or bend having a desired, I,.~J t . --~ ~ radius of curvature such that the positioning of the tampon assembly in the mold cavity causes the tampon assembly to initially adapt to the arcuate orientation of the mold cavity. Therealter, the tampon assembly i5 held in the mold cavity until the tampon assembly cools to a pl~ ' ' reduced t~ ,.alult:.
Lastly, the tampon assembly is removed from ~ mold cavity.
21807~9 I~RlEF DESCRIPTION OF TEIE DRAWINGS
The foregoing and still further the objects and advantages of the present inYention will be more apparent from the following detailed ~ , ' of the preferred ~ ' " of the invention in connection with the ~ , drawings:
s Fig. I is a perspective view of a two-part mold and curved tampon assembly formed therein in accordance with a first preferred ~ " of the present invention;
Fig. 2 is a cut-away view along line 2-2 of Flg. I with the upper and lower molds ofthe two-part mold joined together;
Fig. 3 is an end elevational view of the two-part mold of Fig. 2 with the upper and lower o molds of the two-part mold joined together but with the curved tampon assembly not shown;
Flg. 4 is a perspective view of 8 two-part mold and curved tampon assembly formed therein in accordance with a second preferred L " of the present invention;
Fig 5 is a cut-away view taken along tine 6-6 of Flg. 5 with the upper and lower mold of the two-part mold joined together; and Fig. 6 is a sectional view taken along line 6-6 of Fig. 5 but with the curved tampon assembly not shown;
218~789 Fig. 7 is a cut-away view of a third two-part mold and curved ~ampon assembly formed tllerein in accordance Witll a third preferred (~ ~-'- ~ ' of the present invention;
Fig. 8 is a sectional view of the fingergrip of the curved tampon assembly taken along line 8-8 of Fig. 7 having a circular cross-section; arld Fig. 9 is a sectional view of an alternative to the fingergrip of Fig. 8 having an elliptical ~ ion DETAILED DESCRIPTION OF T~E PR~;~ t;KK~ EMBODIMENTS
Referring to the drawings and, in particular, to Fig. 1, there is provided a tampon assembly which is generally ~,.,-, ' by reference numeral 10. The tampon assembly 10 includes a pledget 11 (sllown in dotted lines in Fig. 2) and an applicator that includes a barrel component 5 and a plunger 14. The barrel component includes a barrel 12 and a fingergrip 16. The applicator is, preferably, madeofplastic, suchas POI~ Jk~ orother~h .".."~ typematerials. There is also provided an apparatus for forming the tampon assembly 10, which apparatus includes a lower mold 18 and an upper mold 24 The barrel 12 and the plunger 14 of the applicator and the pledget 11 are formed using 0 existing " ~r l ...g methods. For example, the applicator may be formed by molding or extrusion using existing tampon " " equipment and known methods for forming a ped tampon . . , ' These, r l.; ~ and assembly equipment and methods are not discussed in detail in t~lis application since they are well known in the art and are not a critical part of the present invention.
AP~er each component of the tampon assembly is formed and the entire tampon assembly 10 is assembled, the present invention is employed. It is to be understood that the process of the present invention lends itself to ~ ~ ~ the axial orientation of one or more - ---r ' of an entire tampon assembly 10 and may be used to change the axial orientation of the entire tampon assembly as well.
218~7~
Referring to the first preferred ~"-~ " shown in Figs. 1 through 3, the barrel 12 will be post formed into a curved or arcuate axial orientation while the plunger 14 remains straight.
The tampon assembly 10 or a portion thereof, such as the barrel 12, is first heated at a ;1 elevated l~ dlUlt: to permit flexing and 1~:~ of the central axis A-A of the tampon assembly. Any t~ pe of ~ . . ' process for elevating the l.,."t).,l ~llul~ of the tampon assembly 10 may be used, such as exposure to a hot air oven or infrared heating, so long as the tampon assembly, and especially the pledget 11, is not harmed or otherwise rendered unusable. Infrared heating is preferred due to its ability to rapidly heat a tampon assembly 10 and direct its heat to desired portions of the tampon assembly. For instance, the ~
heating range is about IS0 degrees to about 250 degrees Fahrenheit for p~ .,ll,yl~,..~.
By lleating the barrel 12 of the tampon assembly 10, the structure of the barrel is softened so tllat it can be curved or otllerwise shaped. This heating is preferably , ' ' ' at a rapid rate so that the cycle time for heating the barrel 12 is mini~nized and excessive quantities of heat energy do not have to be withdrawn from the barrel to set the new axial orientation. To assure that heating is uniform, the tampon assembly 10 is rotated during heating. Preferably, the tampon assembly 10 is rotated at a rotational surface speed from about S to 15 feet per minute for about 10 to ~0 seconds. Also, the cycle time and radiant heat level for heating the barrel 12 is adjusted so that the barrel is heated to a level just below where it will start to soften excessively or become misshaped.
, . 2180789 Referring specifically to Fig. 1, the heated tampon assembly 10 should be transferred to a cooling die, such as the lower mold 18 and the upper mold 24, as rapidly as possible after heating to maintain the utmost efficiency of process. Preferably, the heated barrel 12 should be transferred into the cooling die within about two seconds. During the cooling process, the barrel s 12 and the pledget 11 therein sllall basically take the arcuate axial orientation. Thus, the initially straight formed tampon assembly 10, now having a heated barrel 12, is situated on a :lUb;~klll~i. ~I r cylindrical, curved inner surfa~e 20 of the lower mold 18.
Referring to Figs. 2 and 3, when the lower mold 18 amd the upper mold 24 are joined, they form a mold cavity 30 that compresses the heated tampon assembly 10, and in particular the o lleated barrel 12. The mold cavity 30 has a I n,. ' ' arcuate orientation, represented by centerline A-A, based on a ~ ' ' radius of curvature 34. The level of -,u...~
subjected to the lower mold 18 and the upper mold 24 is sufficient to fully close the two-part mold.
The lower mold 18 and the upper mold 24 are joined together, as stated above, such that an upper shoulder 22 of the lower mold 18 abuts a lower dange or slloulder 28 of the upper mold 24. In tllis joined position, a surface 20 Of the lower mold 18 and a surface 26 0f the upper mold 24 form tlle mold cavity 30 therein. As shown in Fig. 2, the surfaces 20, 26 have an elongated, arcuate shape that, ~ ' each other to for~n a curved cylindrical hole in which the barrel 12 is curved into the desired shape. As noted in Fig. 2, the fingergrip 16 portion of the barrel 12 and 20 the plunger 14 do not contact either the lower mold 18 or the upper mold 24 and therefore their original straight axial ~, -t,r,.. ' and shapes are not affected by the molds.
2180i89 The arcuate shapes of the surfaces 20, 26 are also represented in Fig. 3. In particular, the solid circle 30A formed by the surfaces 20, 26 shows the view of the mold cavity 30 from one end of the two-part mold, while the du ~ aldly offset dashed circle 30B represents the middle cross-section of the mold cavity 30, which is the lowest position of the mold cavity within the two-part 5 mold. Accordingly, the circles 30A and 30B represent the cun$ure of the barrel 12 and the pledget 11 therein.
The heated barrel 12 is . . ~ ,1 and held within the fully closed, non-heated mold cavity 30 until the tampon assembly reaches a ~ reduced t~ UI~. Although a cooling mechanism (not sl~own) for controlling the t~,...l..,.~ul~ ofthe lower mold 18 and!or the u upper mold 24 is not necessary, such a mechanism may be used in order to expedite the cooling process or otherwise increase ~, r For example, a cooling media may be circulated tllroughout the lower mold 18 and the upper mold 24 or the molds may be air cooled. Preferably, in order to sustain a preferred cooling time period of about 35 seconds, a coolant having a constant . ~ about 65 degrees Fahrenheit is circulated through the lower mold 18 and the 5 upper mold 24. For instance, the ~ ' reduced It~ ul~ may range from about 90 degrees to about 150 degrees Fahrenheit for a p~ .L~.,I~,.,~, applicator.
Like the mold cavity 30, the barrel 12 shall have an arcuate shape that Cullt~lJulld~ to centerline A-A while it is positioned within the mold cavity. However, in virtually every instance, the tampon assembly 10 does not take the exact form of the mold cavity 30 since certain 20 materials, such as ~ , have a memory and tend to counter-cune back slightly toward 218078~
their original straight form upon removal from the mold cavity 30 In order to produce a tampon assembly 10 having a particular radius of curvature, the mold cavity 30 where it is formed must llave a sliglltly smaller radius of curvature 34 to ~ -r for offset caused by the memory.
Tlle arcuate shape represented by centerline A-A has a radius of curvature 34 of about 3 inches to s about 6 inches in order to form a final tampon assembly 10 having a radius of curvature of about 5 inches to about 11 inches. Preferably, the radius of curvature 34 of centerline A-A is about 4 incl~es and the radius of curvature of the final tampon assembly is about 10 inches.
A fingergrip 16 is located at one end of the barrel 12 ad~acent the plunger 14. The fingergrip 16 and plunger 14 have a straight form, l~t~ ' by centerline B-B. The plunger 14 to has a diameter 38 that is less tllan a diameter 40 of the fingergrip 16 of the barrel 12. Tlle diameters of the plunger 14 and fingergrip 16 are less than that of the barrel 12 and of such an extent that neither the plunger 14 nor the fingergrip 16 contact any inner surface of the mold cavity 30.
To remove the tampon assembly 10 from the molds, the lower mold 18 is separated from the upper mold 24. The tampon assembly 10 that has been post formed and removed firom the lower and upper molds 18, 24, has a new axial orientation that is, preferably, curved. Since no further ~ ,, or assembly of, , is required, the tampon assembly 10 is ready for packaging and tii~trihl~tjnn In contrast to the first preferred ~ ~ ' t, the ~1,, of the mold cavities for the other preferred; b~ " described below, are different than that of the first preferred 21~078~
tlllbCI '- Tlle specific mold cavities ' '~ affect the steps of positioning and holding of tlle tampon assembly 10. On the other hand, the steps of heating and removing of the tampon assembly 10 for the following ~ ~ - ' are virtually identical to the ~,u,l. r ", steps of the first preferred ~,. .1 .~.1l, 1.. Il as described above. Therefore, only the aspects of positioning 5 and holding of the tampon assembly 10 that differ from the ffrst preferred ~ are discussed below.
Referring to Fig. 4, there is shown a second preferred ,l o~ of the tampon assembly 10 and the two-part mold. For this second preferred ~hufi 1 the upper mold 46 is, preferably, an ~shaped member having an upper or llorizontal portion 47A and an integral o Yertical portion 47 B. The vertical portion 47B includes an aperture 48 adjacent the mold cavhy 50 for supporting the fingergrip 16 and, also, the plunger 14 of the tampon assembly 10. Due to aperture 48 in the upper mold, the lower mold 44 does not assist in curving the shape of the fingergrip 16 of the tampon assembly 10. This aperture serves to hold the fingergrip 16 at a particular angle 56 relative to the tangent line 57 to the centerline A-A of the tampon assembly 10 15 during the cooling step. As a result, the fingergrip 16 and plunger 14 ofthe tampon assembly 10 shall have greater angularity than that of the first preferred . ~ ' Referring to Fig. 5, the inner surfaces of the lower mold 44 and the upper mold 46 that form the mold cavity 50 are used to reshape the barrel 12 of the tampon assembly 10 and fiunction similarly to the w~ JUlldll:~ elements of the first preferred ~ ~ ' Similar to the first 20 preferred 1 ' t, the two-part mold of this second preferred . ' ' does not affect the straight form of the plunger 14. However, one ~ ' ,, ' ,, feature of the second preferred 218078~
c...l., " isthatthefmgergrip 160fthebarrel 12issupportedsolelybytlleaperture480fthe upper mold 46 and introduces a greater angle with respect to the tangent line 57 of the centerline A-A than the firs ~ ~-o~
The outer surface of the fingergrip 16, preferably, has a plurality of ~" uLub~,. or grips s 52. The outside diarneter 40 of the fingergrip 16, as measured at the ~ulub~ 52, is greater than the outside diameter 58 of the remainder of the plunger 14 and is no smaller than, and preferably about the same as, the diameter 54 of the aperture 48. Since tlle diameter 40 of the fingergrip 16 is equal to or greater than the diameter 54 of the aperture 48, the aperture forms a well-supported fit or grip with the ffngergrip 16 to bend or reshape the heated fingergrip.
o This well-supported fit or grip of the fingergrip 16 by aperture 48 holds the tampon securely so that the fingergrip of the barrel 12 is bent at a particular angle 56 relative tû the remainder of the barrel. In comparing Figs. 2 and 6, it can be seen that centerline C-C of tlle plunger 14 and fingergrip 16 of the second preferred ~ ' is bent at a greater angle with respect to the horizontal position than the center line B-B of these cv" ~l v ~ in the first preferred ~;,. ' "
Referring to Fig. 6, the diameter 54 of the aperture 48 of the upper mold 46 is shown relative to the diameter 42 of the mold cavity 50. The constricted or narrower size of the aperture 48 is necessary to grip or position of the fingergrip 16 by the upper mold 46, as described above.
Referring to Fig. 7, there is shown a third preferred ~..L,- ' of tlle two-part mold and tampon assembly of the present invention. The third preferred, ' ' provides for post forming tlle entire tampon assembly 10, i.e. the barrel 12 with tampon pledget 11 and the plunger 14, into a curved tampon assembly. Thus, the entire tampon assembly 10 is post-formed into 5 virtually a single ~,. tl~ radius of curvature 34. In particular, it is intended that the centerline of the barrel 12, the fingergrip 16 and the plunger 14 is the same so that a single radius of curvature 34 as shown by centerline D-D is achieved for the Gntire tampon assembly 10.
To achieve the ' reshaping or bending of the entire tampon assembly 10, the upper and lower molds include three sections of mating inner surfaces 76, 7g & 80. Imner o surfaces 76 form mold caYity 70 the tampon barrel 12, inner surfaces 7g form a cavity 7~ for the fingergrip 16, while inner surfaces 80 form a cavity 74 for the plunger 14. In each instance, the inner surfaces 76, 78 & 80 contact the heated portion of the tampon assembly 10, namely the barrel 12, tlle fingergrip 16 and tlle plunger 14, to reshape or curve the axial orientation oftllat t~ -r s In order to form the curved plunger 14 of the third preferred ' ' t, the plunger is heated ' '~, with the barrel 12 before being positioned in the molds 64, 66. After pheitinnin~, the barrel 12 is ~U~ too~ within the mold cavity 70, the plunger 14 is cu~ e~J
within cavity 74 and the fingergrip 16 is I~UIIIIJlI,v~_J within cavity 72. These portions ofthe tampon assembly 10 are held within their respective cavities until the tampon assembly reaches the ~ ' ' reduced i . 'I t;. Accordingly, when the tampon assembly 10 is removed, it ,-- ' ' , 2l8o78g will ~ , correspond with the curved shape of the cavities 72, 74 defined by centerlines A-A and D-D.
To curve the axis of tlle plunger 14, cavity 74 must be long enough to enclose the entire plunger, as shown in Fig. 7. This is in contrast to the shorter mold l,UIIail ul,liull of the first preferred ~ udill~ lL wllere the plunger 14 extends out of one end of the two-part mold 18, 24, as sllown in Fig. 2.
Referring to Figs. 7 through 9, the cavity 74 for the plunger 14 and the cavity 72 for the fingergrip 16 form the cross-section of the plunger and the fingergrip into a ~ d~t~ ' geometric sllape. The present invention is not limited to objects or d~ ,~ h~ ~ a circular o cross-section. Tl~e post-forming process of the present invention performs well for objects or devices having a cross-section that is oval, square, or otherwise non-circular in shape. In Fig. 8, tlle cavity 72 for tile fingergrip 16 encloses the fingergrip, as weli as a portion of the plunger 14 that is situated im the fingergrip, to form a circular, cross-sectionai shape for the fingergrip and a similar circular, cross-sectionai shape for the plunger. The present invention provides a metl1od to form a wide variety of different geometric shapes for the fingergrip 16 and the plunger 14 of the tampon assembly 10. By example, the fingergrip 16 and the plunger 14 may have an ellipticai, cross-sectionai shape as shown in Fig. 9.
The lowe~ molds 18, 44 & 64 and upper molds 24, 46 & 66 of each . 1 " of the present invention may be made of any type of materiai or materiais that may handle the tampon assembly 10 after the heating process described above. In particular, the material must be capable of being machined to a desired shape and conducting heat away from the tampon assembly 10 at a Mpid rate. In addition, each mold cavity of each ~ ' ~ " must be capable of ~.ul~lU~ the desired portions ofthe tampon assembly 10 as described above during the ~.ulllu~ ' ,, process.
The acceptable materials include, but are not limited to, metallic materials, and preferably 5 aluminum.
Tlle barrel 12 including the integral fingergrip 16 and the plunger 14 of the tampon assembly 10 may be made of any type of material or materials that may be injection molded or extruded. The materials must be heat resistant to the elevated t~ ul 1,., of the heating process and tension resistant to the pressure leYels of the ~,U...~ ' ,, process, which processes have been lo described above. The materials include, but are not limited to" h ~ ,pl ~
The pledget 11 may be made of any type of soR material that curves naturally within the barrel 12 during the methods of the present invention. These materials include, but are not limited to, cotton, ~ullu.l~l~ull blends, and rayon. Also, it has been determined that, in addition to utilizing a soft material, lengthening and thinning the dimensions of the pledget 11 permits it to 5 move freely within the barrel. This free movement facilitates formation of its curved shape during tlle Culllul U.~ ll of tlle barrel in the two-part mold and ejection of the pledget 11 from the barrel.
In summary, the post forming steps, i.e., steps executed after assembly of the ~ - --r of the tampon assembly 10, provide an efficient and economical method of producing a curved tampon assembly. The method, which includes heating, ~ ~, holding during cool-down 20 and removing the tampon assembly 10, causes a second or 1.;... ~ .... of the tampon assembly 21807~g into a new axial orientation, preferably called a curved shape, without the need to purchase or otherwise obtain '` ,, and asæmbling equipment that are specially designed to handle curved ~ , While this application presents a first preferred ~ 1 " shown in Figs. I through 3, a 5 second preferred L ' shown in Figs. 4 through 6, and a third preferred .
sllown in hgs. 7 through 9, other possible ~ ' ' not explicitly sllown can be derived based on these b~ "
It is to be understood that the post-forming or axial IrO~ o~ process of the present inYention is not intended to be limited to tampon assemblies. It is .,(~ that the above-o described process may be used to reconfigure a wide variety of objects or devices that may desirea new shape, particularly a curved shape.
The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and .... ~ may be made therein with~l d~pmting f m f e ~pilit =d t ope of tb~ mw ntiwm :s ~edned in the t pp mdt d clldms.
BACKGROUND O~7 TIIE INVE;NTION
I. Field of the Invention The present invention relates generally to tampon assemblies including an applicator and a 5 pledget for vaginal insertion of tampon pledgets. More particularly, the present invention relates to a method for post forming a plastic-type tampon assembly into a curvcd axial orientation but aRer tl~e initial formation and assembly of the hmpon assembly ---r ' into a normal, straight-formed hmpon assembly.
II. Description of the Prior Art o Generally, methods for forming curved-type tampons pledgets are known. For example, U.S. Patent No. 5,153,971 to T.P. Van Iten, which issued on October 13, 1992, and related U.S.
Patent No. 5,350,371 to also T.P. Van Iten, which issued on September 27, 1994, provide a method for forming a curved hmpon pledget. The pledget is constructed having two dif`erent zones of fiber density and inserted into a mold cavity having two open ends. Then, the pledget is ~ . ~D~i~ at both open ends and, optionally, heated about its periphery within the mold cavity.
Next, the pledget exits the mold cavity having a straight form but quickly blossoms into a curved shaped pledget due to the differing expansion properties of its two ~ones of fiber density.
I
,-- . 2~8078g Thereafter, the pledget may be positioned within a curved tampon applicator to complete assembly of the tampon assembly.
In addition to curved-type tampon pledgets, methods for forming curved plashc tampon applicators for inserting pledgets are also known. Such tampon applicators are typically s ~ ~1 using curved plastic UUIIII. ', such as a barrels and plungers, that are molded or extruded in a ~ ' ' curved ~ - and then assembled with the pledget to proYide tl~e fnished curved tampon applicator product. For example, U.S. Patent No. 5,158,535 to S.C.
Paul, et al., which issued on October 27, 1992, and U.S. Patent No. 5,267,953 to also S.C. Paul, et al., which issued on December 7, 1993 and is a divisional based on the U.S. Patent No.
5,158,535,provideamethodforforiningabarrelandplungerofacurvedtamponapplicatorby injection molding or extrusion. The straight barrel and plunger are individually heat set into an arcuate axial orientation. The barrel has a degree of axial curvature that is greater than that of its original shape. Then, the plunger is inserted into one end of the barrel and, thereafter, a tampon pledget is assembled within the other end of the barrel to complete the formation of the tampon assembly.
The above patents describe processes for forming curved, . such as the pledget, barrel and plunger, that are " 'J, assembled together. Such assembly . ' production and is more difficult since . ' ", sorting and orienting such curved ~ .
requires special attention and expensive assembly machinery. In addition, the formation through 20 the use of curved molds is more difficult than - ' straight cu~ u~
21807g9 Therefore, there is a necd for a new and improved method for permitting tampon --r ' to be IllailuL~,tu~ as existing straight cy.indrica~ t` and assembled using pr~t " ' ' high speed assembly methods while, ~, .1.,~7.~.. - ' 1~, reforming or reorienting the complete tampon assembly into a curved ~ fi~ without further ~ ' v or assembly 5 of 4" ~ t`i SUMMARY OF TlIE INVENTION
Against the foregoing ~al~L~ 1, it is a prima.-y object of the present invention to provide a method of post forming a cu.. . ~ h,ll~, axially straight, plastic-type tampon assembly into an axially curved t.-.mpon assembly.
o It is another object of the present invention to provide such a method for post forming into a curved tampon assembly that is ef.icient and æ
It is a furt.L.er object of tlle present invention to provide such a method for post forming into a curved tampon assembly that permits existing high speed equipment to be used to cllli~i~.lUit; and assemble the ., ~ of the tampon assembly thereby eliminating the need for curved cavity injection molds, plastic I ' ' ~, and orienting equipment, and new or modified assemb.ing machines for curved: .
To accomplish the foregoing objects and advantages, the present invention, in brief summary, comprises the following steps: heating a portion of the formed tampon assembly to a ' elevated ~ .dlUlC, to permit the portion to flex and thereby reorient the axis of the portion. The portion of the tampon assembly is then positioned in a mold cavity that has a 5 Inng " ~ arcuate shape or bend having a desired, 1,.. . ~ radius of curvature such that the positioning of the portion of the tampon assembly in the mold cavity causes the portion to initially adapt to the arcuate orientation of the mold cavity. Thereafter, the portion of the tampon assembly is held in the mold cavity until the tampon assembly cools to a ~..cl' ' reduced . alulc . Lastly, the portion of the tampon assembly is removed from the mold cavity.
o For another; S~ ' . t, the present invention comprises the 6110wing steps: heating a formed tampon assembly that includes a tampon pledget and a tampon applicator to a ,t~ ' elevated i . ~, to permit the tampon assembly to flex and thereby reorient tlle axis of the tampon assembly. The tampon assembly is then positioned in a mold cavity that has a ~ " ' arcuate shape or bend having a desired, I,.~J t . --~ ~ radius of curvature such that the positioning of the tampon assembly in the mold cavity causes the tampon assembly to initially adapt to the arcuate orientation of the mold cavity. Therealter, the tampon assembly i5 held in the mold cavity until the tampon assembly cools to a pl~ ' ' reduced t~ ,.alult:.
Lastly, the tampon assembly is removed from ~ mold cavity.
21807~9 I~RlEF DESCRIPTION OF TEIE DRAWINGS
The foregoing and still further the objects and advantages of the present inYention will be more apparent from the following detailed ~ , ' of the preferred ~ ' " of the invention in connection with the ~ , drawings:
s Fig. I is a perspective view of a two-part mold and curved tampon assembly formed therein in accordance with a first preferred ~ " of the present invention;
Fig. 2 is a cut-away view along line 2-2 of Flg. I with the upper and lower molds ofthe two-part mold joined together;
Fig. 3 is an end elevational view of the two-part mold of Fig. 2 with the upper and lower o molds of the two-part mold joined together but with the curved tampon assembly not shown;
Flg. 4 is a perspective view of 8 two-part mold and curved tampon assembly formed therein in accordance with a second preferred L " of the present invention;
Fig 5 is a cut-away view taken along tine 6-6 of Flg. 5 with the upper and lower mold of the two-part mold joined together; and Fig. 6 is a sectional view taken along line 6-6 of Fig. 5 but with the curved tampon assembly not shown;
218~789 Fig. 7 is a cut-away view of a third two-part mold and curved ~ampon assembly formed tllerein in accordance Witll a third preferred (~ ~-'- ~ ' of the present invention;
Fig. 8 is a sectional view of the fingergrip of the curved tampon assembly taken along line 8-8 of Fig. 7 having a circular cross-section; arld Fig. 9 is a sectional view of an alternative to the fingergrip of Fig. 8 having an elliptical ~ ion DETAILED DESCRIPTION OF T~E PR~;~ t;KK~ EMBODIMENTS
Referring to the drawings and, in particular, to Fig. 1, there is provided a tampon assembly which is generally ~,.,-, ' by reference numeral 10. The tampon assembly 10 includes a pledget 11 (sllown in dotted lines in Fig. 2) and an applicator that includes a barrel component 5 and a plunger 14. The barrel component includes a barrel 12 and a fingergrip 16. The applicator is, preferably, madeofplastic, suchas POI~ Jk~ orother~h .".."~ typematerials. There is also provided an apparatus for forming the tampon assembly 10, which apparatus includes a lower mold 18 and an upper mold 24 The barrel 12 and the plunger 14 of the applicator and the pledget 11 are formed using 0 existing " ~r l ...g methods. For example, the applicator may be formed by molding or extrusion using existing tampon " " equipment and known methods for forming a ped tampon . . , ' These, r l.; ~ and assembly equipment and methods are not discussed in detail in t~lis application since they are well known in the art and are not a critical part of the present invention.
AP~er each component of the tampon assembly is formed and the entire tampon assembly 10 is assembled, the present invention is employed. It is to be understood that the process of the present invention lends itself to ~ ~ ~ the axial orientation of one or more - ---r ' of an entire tampon assembly 10 and may be used to change the axial orientation of the entire tampon assembly as well.
218~7~
Referring to the first preferred ~"-~ " shown in Figs. 1 through 3, the barrel 12 will be post formed into a curved or arcuate axial orientation while the plunger 14 remains straight.
The tampon assembly 10 or a portion thereof, such as the barrel 12, is first heated at a ;1 elevated l~ dlUlt: to permit flexing and 1~:~ of the central axis A-A of the tampon assembly. Any t~ pe of ~ . . ' process for elevating the l.,."t).,l ~llul~ of the tampon assembly 10 may be used, such as exposure to a hot air oven or infrared heating, so long as the tampon assembly, and especially the pledget 11, is not harmed or otherwise rendered unusable. Infrared heating is preferred due to its ability to rapidly heat a tampon assembly 10 and direct its heat to desired portions of the tampon assembly. For instance, the ~
heating range is about IS0 degrees to about 250 degrees Fahrenheit for p~ .,ll,yl~,..~.
By lleating the barrel 12 of the tampon assembly 10, the structure of the barrel is softened so tllat it can be curved or otllerwise shaped. This heating is preferably , ' ' ' at a rapid rate so that the cycle time for heating the barrel 12 is mini~nized and excessive quantities of heat energy do not have to be withdrawn from the barrel to set the new axial orientation. To assure that heating is uniform, the tampon assembly 10 is rotated during heating. Preferably, the tampon assembly 10 is rotated at a rotational surface speed from about S to 15 feet per minute for about 10 to ~0 seconds. Also, the cycle time and radiant heat level for heating the barrel 12 is adjusted so that the barrel is heated to a level just below where it will start to soften excessively or become misshaped.
, . 2180789 Referring specifically to Fig. 1, the heated tampon assembly 10 should be transferred to a cooling die, such as the lower mold 18 and the upper mold 24, as rapidly as possible after heating to maintain the utmost efficiency of process. Preferably, the heated barrel 12 should be transferred into the cooling die within about two seconds. During the cooling process, the barrel s 12 and the pledget 11 therein sllall basically take the arcuate axial orientation. Thus, the initially straight formed tampon assembly 10, now having a heated barrel 12, is situated on a :lUb;~klll~i. ~I r cylindrical, curved inner surfa~e 20 of the lower mold 18.
Referring to Figs. 2 and 3, when the lower mold 18 amd the upper mold 24 are joined, they form a mold cavity 30 that compresses the heated tampon assembly 10, and in particular the o lleated barrel 12. The mold cavity 30 has a I n,. ' ' arcuate orientation, represented by centerline A-A, based on a ~ ' ' radius of curvature 34. The level of -,u...~
subjected to the lower mold 18 and the upper mold 24 is sufficient to fully close the two-part mold.
The lower mold 18 and the upper mold 24 are joined together, as stated above, such that an upper shoulder 22 of the lower mold 18 abuts a lower dange or slloulder 28 of the upper mold 24. In tllis joined position, a surface 20 Of the lower mold 18 and a surface 26 0f the upper mold 24 form tlle mold cavity 30 therein. As shown in Fig. 2, the surfaces 20, 26 have an elongated, arcuate shape that, ~ ' each other to for~n a curved cylindrical hole in which the barrel 12 is curved into the desired shape. As noted in Fig. 2, the fingergrip 16 portion of the barrel 12 and 20 the plunger 14 do not contact either the lower mold 18 or the upper mold 24 and therefore their original straight axial ~, -t,r,.. ' and shapes are not affected by the molds.
2180i89 The arcuate shapes of the surfaces 20, 26 are also represented in Fig. 3. In particular, the solid circle 30A formed by the surfaces 20, 26 shows the view of the mold cavity 30 from one end of the two-part mold, while the du ~ aldly offset dashed circle 30B represents the middle cross-section of the mold cavity 30, which is the lowest position of the mold cavity within the two-part 5 mold. Accordingly, the circles 30A and 30B represent the cun$ure of the barrel 12 and the pledget 11 therein.
The heated barrel 12 is . . ~ ,1 and held within the fully closed, non-heated mold cavity 30 until the tampon assembly reaches a ~ reduced t~ UI~. Although a cooling mechanism (not sl~own) for controlling the t~,...l..,.~ul~ ofthe lower mold 18 and!or the u upper mold 24 is not necessary, such a mechanism may be used in order to expedite the cooling process or otherwise increase ~, r For example, a cooling media may be circulated tllroughout the lower mold 18 and the upper mold 24 or the molds may be air cooled. Preferably, in order to sustain a preferred cooling time period of about 35 seconds, a coolant having a constant . ~ about 65 degrees Fahrenheit is circulated through the lower mold 18 and the 5 upper mold 24. For instance, the ~ ' reduced It~ ul~ may range from about 90 degrees to about 150 degrees Fahrenheit for a p~ .L~.,I~,.,~, applicator.
Like the mold cavity 30, the barrel 12 shall have an arcuate shape that Cullt~lJulld~ to centerline A-A while it is positioned within the mold cavity. However, in virtually every instance, the tampon assembly 10 does not take the exact form of the mold cavity 30 since certain 20 materials, such as ~ , have a memory and tend to counter-cune back slightly toward 218078~
their original straight form upon removal from the mold cavity 30 In order to produce a tampon assembly 10 having a particular radius of curvature, the mold cavity 30 where it is formed must llave a sliglltly smaller radius of curvature 34 to ~ -r for offset caused by the memory.
Tlle arcuate shape represented by centerline A-A has a radius of curvature 34 of about 3 inches to s about 6 inches in order to form a final tampon assembly 10 having a radius of curvature of about 5 inches to about 11 inches. Preferably, the radius of curvature 34 of centerline A-A is about 4 incl~es and the radius of curvature of the final tampon assembly is about 10 inches.
A fingergrip 16 is located at one end of the barrel 12 ad~acent the plunger 14. The fingergrip 16 and plunger 14 have a straight form, l~t~ ' by centerline B-B. The plunger 14 to has a diameter 38 that is less tllan a diameter 40 of the fingergrip 16 of the barrel 12. Tlle diameters of the plunger 14 and fingergrip 16 are less than that of the barrel 12 and of such an extent that neither the plunger 14 nor the fingergrip 16 contact any inner surface of the mold cavity 30.
To remove the tampon assembly 10 from the molds, the lower mold 18 is separated from the upper mold 24. The tampon assembly 10 that has been post formed and removed firom the lower and upper molds 18, 24, has a new axial orientation that is, preferably, curved. Since no further ~ ,, or assembly of, , is required, the tampon assembly 10 is ready for packaging and tii~trihl~tjnn In contrast to the first preferred ~ ~ ' t, the ~1,, of the mold cavities for the other preferred; b~ " described below, are different than that of the first preferred 21~078~
tlllbCI '- Tlle specific mold cavities ' '~ affect the steps of positioning and holding of tlle tampon assembly 10. On the other hand, the steps of heating and removing of the tampon assembly 10 for the following ~ ~ - ' are virtually identical to the ~,u,l. r ", steps of the first preferred ~,. .1 .~.1l, 1.. Il as described above. Therefore, only the aspects of positioning 5 and holding of the tampon assembly 10 that differ from the ffrst preferred ~ are discussed below.
Referring to Fig. 4, there is shown a second preferred ,l o~ of the tampon assembly 10 and the two-part mold. For this second preferred ~hufi 1 the upper mold 46 is, preferably, an ~shaped member having an upper or llorizontal portion 47A and an integral o Yertical portion 47 B. The vertical portion 47B includes an aperture 48 adjacent the mold cavhy 50 for supporting the fingergrip 16 and, also, the plunger 14 of the tampon assembly 10. Due to aperture 48 in the upper mold, the lower mold 44 does not assist in curving the shape of the fingergrip 16 of the tampon assembly 10. This aperture serves to hold the fingergrip 16 at a particular angle 56 relative to the tangent line 57 to the centerline A-A of the tampon assembly 10 15 during the cooling step. As a result, the fingergrip 16 and plunger 14 ofthe tampon assembly 10 shall have greater angularity than that of the first preferred . ~ ' Referring to Fig. 5, the inner surfaces of the lower mold 44 and the upper mold 46 that form the mold cavity 50 are used to reshape the barrel 12 of the tampon assembly 10 and fiunction similarly to the w~ JUlldll:~ elements of the first preferred ~ ~ ' Similar to the first 20 preferred 1 ' t, the two-part mold of this second preferred . ' ' does not affect the straight form of the plunger 14. However, one ~ ' ,, ' ,, feature of the second preferred 218078~
c...l., " isthatthefmgergrip 160fthebarrel 12issupportedsolelybytlleaperture480fthe upper mold 46 and introduces a greater angle with respect to the tangent line 57 of the centerline A-A than the firs ~ ~-o~
The outer surface of the fingergrip 16, preferably, has a plurality of ~" uLub~,. or grips s 52. The outside diarneter 40 of the fingergrip 16, as measured at the ~ulub~ 52, is greater than the outside diameter 58 of the remainder of the plunger 14 and is no smaller than, and preferably about the same as, the diameter 54 of the aperture 48. Since tlle diameter 40 of the fingergrip 16 is equal to or greater than the diameter 54 of the aperture 48, the aperture forms a well-supported fit or grip with the ffngergrip 16 to bend or reshape the heated fingergrip.
o This well-supported fit or grip of the fingergrip 16 by aperture 48 holds the tampon securely so that the fingergrip of the barrel 12 is bent at a particular angle 56 relative tû the remainder of the barrel. In comparing Figs. 2 and 6, it can be seen that centerline C-C of tlle plunger 14 and fingergrip 16 of the second preferred ~ ' is bent at a greater angle with respect to the horizontal position than the center line B-B of these cv" ~l v ~ in the first preferred ~;,. ' "
Referring to Fig. 6, the diameter 54 of the aperture 48 of the upper mold 46 is shown relative to the diameter 42 of the mold cavity 50. The constricted or narrower size of the aperture 48 is necessary to grip or position of the fingergrip 16 by the upper mold 46, as described above.
Referring to Fig. 7, there is shown a third preferred ~..L,- ' of tlle two-part mold and tampon assembly of the present invention. The third preferred, ' ' provides for post forming tlle entire tampon assembly 10, i.e. the barrel 12 with tampon pledget 11 and the plunger 14, into a curved tampon assembly. Thus, the entire tampon assembly 10 is post-formed into 5 virtually a single ~,. tl~ radius of curvature 34. In particular, it is intended that the centerline of the barrel 12, the fingergrip 16 and the plunger 14 is the same so that a single radius of curvature 34 as shown by centerline D-D is achieved for the Gntire tampon assembly 10.
To achieve the ' reshaping or bending of the entire tampon assembly 10, the upper and lower molds include three sections of mating inner surfaces 76, 7g & 80. Imner o surfaces 76 form mold caYity 70 the tampon barrel 12, inner surfaces 7g form a cavity 7~ for the fingergrip 16, while inner surfaces 80 form a cavity 74 for the plunger 14. In each instance, the inner surfaces 76, 78 & 80 contact the heated portion of the tampon assembly 10, namely the barrel 12, tlle fingergrip 16 and tlle plunger 14, to reshape or curve the axial orientation oftllat t~ -r s In order to form the curved plunger 14 of the third preferred ' ' t, the plunger is heated ' '~, with the barrel 12 before being positioned in the molds 64, 66. After pheitinnin~, the barrel 12 is ~U~ too~ within the mold cavity 70, the plunger 14 is cu~ e~J
within cavity 74 and the fingergrip 16 is I~UIIIIJlI,v~_J within cavity 72. These portions ofthe tampon assembly 10 are held within their respective cavities until the tampon assembly reaches the ~ ' ' reduced i . 'I t;. Accordingly, when the tampon assembly 10 is removed, it ,-- ' ' , 2l8o78g will ~ , correspond with the curved shape of the cavities 72, 74 defined by centerlines A-A and D-D.
To curve the axis of tlle plunger 14, cavity 74 must be long enough to enclose the entire plunger, as shown in Fig. 7. This is in contrast to the shorter mold l,UIIail ul,liull of the first preferred ~ udill~ lL wllere the plunger 14 extends out of one end of the two-part mold 18, 24, as sllown in Fig. 2.
Referring to Figs. 7 through 9, the cavity 74 for the plunger 14 and the cavity 72 for the fingergrip 16 form the cross-section of the plunger and the fingergrip into a ~ d~t~ ' geometric sllape. The present invention is not limited to objects or d~ ,~ h~ ~ a circular o cross-section. Tl~e post-forming process of the present invention performs well for objects or devices having a cross-section that is oval, square, or otherwise non-circular in shape. In Fig. 8, tlle cavity 72 for tile fingergrip 16 encloses the fingergrip, as weli as a portion of the plunger 14 that is situated im the fingergrip, to form a circular, cross-sectionai shape for the fingergrip and a similar circular, cross-sectionai shape for the plunger. The present invention provides a metl1od to form a wide variety of different geometric shapes for the fingergrip 16 and the plunger 14 of the tampon assembly 10. By example, the fingergrip 16 and the plunger 14 may have an ellipticai, cross-sectionai shape as shown in Fig. 9.
The lowe~ molds 18, 44 & 64 and upper molds 24, 46 & 66 of each . 1 " of the present invention may be made of any type of materiai or materiais that may handle the tampon assembly 10 after the heating process described above. In particular, the material must be capable of being machined to a desired shape and conducting heat away from the tampon assembly 10 at a Mpid rate. In addition, each mold cavity of each ~ ' ~ " must be capable of ~.ul~lU~ the desired portions ofthe tampon assembly 10 as described above during the ~.ulllu~ ' ,, process.
The acceptable materials include, but are not limited to, metallic materials, and preferably 5 aluminum.
Tlle barrel 12 including the integral fingergrip 16 and the plunger 14 of the tampon assembly 10 may be made of any type of material or materials that may be injection molded or extruded. The materials must be heat resistant to the elevated t~ ul 1,., of the heating process and tension resistant to the pressure leYels of the ~,U...~ ' ,, process, which processes have been lo described above. The materials include, but are not limited to" h ~ ,pl ~
The pledget 11 may be made of any type of soR material that curves naturally within the barrel 12 during the methods of the present invention. These materials include, but are not limited to, cotton, ~ullu.l~l~ull blends, and rayon. Also, it has been determined that, in addition to utilizing a soft material, lengthening and thinning the dimensions of the pledget 11 permits it to 5 move freely within the barrel. This free movement facilitates formation of its curved shape during tlle Culllul U.~ ll of tlle barrel in the two-part mold and ejection of the pledget 11 from the barrel.
In summary, the post forming steps, i.e., steps executed after assembly of the ~ - --r of the tampon assembly 10, provide an efficient and economical method of producing a curved tampon assembly. The method, which includes heating, ~ ~, holding during cool-down 20 and removing the tampon assembly 10, causes a second or 1.;... ~ .... of the tampon assembly 21807~g into a new axial orientation, preferably called a curved shape, without the need to purchase or otherwise obtain '` ,, and asæmbling equipment that are specially designed to handle curved ~ , While this application presents a first preferred ~ 1 " shown in Figs. I through 3, a 5 second preferred L ' shown in Figs. 4 through 6, and a third preferred .
sllown in hgs. 7 through 9, other possible ~ ' ' not explicitly sllown can be derived based on these b~ "
It is to be understood that the post-forming or axial IrO~ o~ process of the present inYention is not intended to be limited to tampon assemblies. It is .,(~ that the above-o described process may be used to reconfigure a wide variety of objects or devices that may desirea new shape, particularly a curved shape.
The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and .... ~ may be made therein with~l d~pmting f m f e ~pilit =d t ope of tb~ mw ntiwm :s ~edned in the t pp mdt d clldms.
Claims (25)
1. A method for post forming a portion of a tampon assembly into a curved axial orientation, the method comprising the steps of:
heating said portion of said tampon assembly to a predetermined elevated temperature to permit flexing and reorienting of an axis of said portion;
positioning said portion of said tampon assembly in a mold cavity having a longitudinal arcuate orientation based on a predetermined radius of curvature, said positioning causing said portion of said tampon assembly to initially adapt to the arcuate orientation of said mold cavity;
holding said portion of said tampon assembly in said mold cavity until said portion cools to a predetermined reduced temperature; and removing said portion from said mold cavity, wherein said removed portion has a curved axial orientation.
heating said portion of said tampon assembly to a predetermined elevated temperature to permit flexing and reorienting of an axis of said portion;
positioning said portion of said tampon assembly in a mold cavity having a longitudinal arcuate orientation based on a predetermined radius of curvature, said positioning causing said portion of said tampon assembly to initially adapt to the arcuate orientation of said mold cavity;
holding said portion of said tampon assembly in said mold cavity until said portion cools to a predetermined reduced temperature; and removing said portion from said mold cavity, wherein said removed portion has a curved axial orientation.
2. The method for post forming of claim 1, wherein said portion of said tampon assembly comprises at least one tampon assembly component selected from the group consisting of: a barrel of a barrel component, a fingergrip of a barrel component and a plunger.
3. The method for post forming of claim 1, wherein said step of positioning said portion of said tampon assembly in said mold cavity includes compressing said portion between an upper mold and a lower mold, wherein said upper mold and said lower mold form said longitudinal arcuate orientation of said mold cavity when said portion is fully compressed therebetween.
4. The method for post forming of claim 3, wherein said step of positioning said portion of said tampon assembly in said mold cavity includes situating said tampon assembly on said lower mold before compressing said portion between said upper mold and said lower mold.
5. The method for post forming of claim 3, wherein said step of positioning said portion of said tampon assembly in said mold cavity includes situating said tampon assembly on said upper mold before compressing said portion between said upper mold and said lower mold.
6. The method for post forming of claim 1, wherein said step of positioning said portion of said tampon assembly in said mold cavity includes compressing a fingergrip of a barrel component of said tampon assembly between said upper mold and said lower mold, wherein a cross-section of said fingergrip is formed into a predetermined shape.
7. The method of post forming of claim 1, wherein said step of positioning said portion of said tampon assembly in said mold cavity includes positioning an end portion of a plunger of said tampon assembly in a fingergrip of a barrel component of said tampon assembly and compressing said plunger and said fingergrip between said upper mold and said lower mold, wherein cross-sections of said plunger and said fingergrip are formed into similar predetermined shapes.
8. The method for post forming of claim 3, wherein said step of positioning said portion of said tampon assembly in said mold cavity includes gripping a fingergrip of a barrel component of said tampon assembly, before compressing said portion, to provide greater angularity between said fingergrip and the remainder of said barrel component of said tampon assembly.
9. The method for post forming of claim 8, wherein said step of gripping said fingergrip of said tampon assembly includes gripping at least one protrusion formed on an outer surface of said fingergrip to facilitate gripping thereof.
10. The method for post forming of claim 8, wherein said step of gripping said fingergrip of said tampon assembly includes bending said fingergrip at a particular angle relative to the remainder of said barrel component of said tampon assembly.
11. The method for post forming of claim 1, further comprising a step of packaging said tampon assembly, directly after removing said tampon assembly from said mold cavity.
12. The method for post forming of claim 1, wherein said predetermined elevated temperatures is about 150 degrees to about 250 degrees Fahrenheit.
13. The method for post forming of claim 1, wherein said predetermined reduced temperature is about 90 degrees to about 150 degrees Fahrenheit.
14. The method for post forming of claim 1, wherein said predetermined radius of curvature of said longitudinal arcuate orientation is about 3 inches to about 6 inches.
15. The method for post forming of claim 1, wherein said curved axial orientation of said removed portion has a desired radius of curvature of about 5 inches to about 11 inches.
16. A method for post forming a tampon assembly including an applicator with a pledget therein into a curved tampon assembly, the method comprising the steps of:
heating said tampon assembly to a predetermined elevated temperature to permit flexing and reorienting of an axis of said tampon assembly;
positioning said tampon assembly in a mold cavity having a longitudinal arcuate orientation based on a predetermined radius of curvature, said positioning causing said tampon assembly to initially adapt to the arcuate orientation of said mold cavity;
holding said tampon assembly in said mold cavity until said tampon assembly cools to a predetermined reduced temperature; and removing said tampon assembly from said mold cavity, wherein said removed tampon assembly has a curved axial orientation.
heating said tampon assembly to a predetermined elevated temperature to permit flexing and reorienting of an axis of said tampon assembly;
positioning said tampon assembly in a mold cavity having a longitudinal arcuate orientation based on a predetermined radius of curvature, said positioning causing said tampon assembly to initially adapt to the arcuate orientation of said mold cavity;
holding said tampon assembly in said mold cavity until said tampon assembly cools to a predetermined reduced temperature; and removing said tampon assembly from said mold cavity, wherein said removed tampon assembly has a curved axial orientation.
17. The method for post forming of claim 16, wherein said tampon assembly comprises a barrel, a fingergrip and a plunger.
18. The method for post forming of claim 16, wherein said step of positioning said tampon assembly in said mold cavity includes compressing said tampon assembly between an upper mold and a lower mold, wherein said upper mold and said lower mold form said longitudinal arcuate orientation of said mold cavity when said tampon assembly is fully compressed therebetween.
19. The method for post forming of claim 16, wherein said step of positioning said tampon assembly in said mold cavity includes compressing a fingergrip of a barrel component of said tampon assembly between said upper mold and said lower mold, wherein a cross-section of said fingergrip is formed into a predetermined shape.
20. The method of post forming of claim 16, wherein said step of positioning said tampon assembly in said mold cavity includes positioning an end portion of a plunger of said tampon assembly in a fingergrip of a barrel component of said tampon assembly and compressing said plunger and said fingergrip between said upper mold and said lower mold, wherein cross-sections of said plunger and said fingergrip are formed into similar predetermined shapes.
21. The method for post forming of claim 16, further comprising a step of packaging said tampon assembly, directly after removing said tampon assembly from said mold cavity.
22. The method for post forming of claim 16, wherein said predetermined elevated temperatures is about 150 degrees to about 250 degrees Fahrenheit.
23. The method for post forming of claim 16, wherein said predetermined reduced temperature is about 90 degrees to about 150 degrees Fahrenheit.
24. The method for post forming of claim 16, wherein said predetermined radius of curvature of said longitudinal arcuate orientation is about 3 inches to about 6 inches.
25. The method for post forming of claim 16, wherein said curved axial orientation of said removed portion has a desired radius of curvature of about 5 inches to about 11 inches.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US50015995A | 1995-07-11 | 1995-07-11 | |
| US08/500,159 | 1995-07-11 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2180789A1 CA2180789A1 (en) | 1997-01-12 |
| CA2180789C true CA2180789C (en) | 2000-10-10 |
Family
ID=23988296
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002180789A Expired - Fee Related CA2180789C (en) | 1995-07-11 | 1996-07-09 | Post formed curved tampon assembly |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US5788910A (en) |
| CA (1) | CA2180789C (en) |
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|---|---|---|---|---|
| GB2418928B (en) * | 2003-06-27 | 2007-01-10 | Playtex Products Inc | Tampon pledget having a shaped tip and method of making same |
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| JP3544139B2 (en) * | 1998-04-13 | 2004-07-21 | キヤノン株式会社 | Optical component, optical component molding method, and optical component molding die |
| ATE314834T1 (en) | 2001-08-16 | 2006-02-15 | Peter James Brian Lamb | APPLICATOR FOR INSERTING AN OBJECT INTO THE VAGINA |
| US7047608B2 (en) * | 2002-03-18 | 2006-05-23 | The Procter & Gamble Company | Method of producing a shaped tampon |
| US7727208B2 (en) | 2002-09-12 | 2010-06-01 | Playtex Products, Inc. | Ergonomic tampon applicator |
| US9192522B2 (en) | 2003-05-02 | 2015-11-24 | Eveready Battery Company, Inc. | Tampon assembly having shaped pledget |
| US20050113787A1 (en) * | 2003-11-21 | 2005-05-26 | The Procter & Gamble Company | Tampon with diverse surface areas |
| US20050113780A1 (en) * | 2003-11-21 | 2005-05-26 | The Procter & Gamble Company | Tampon |
| US7070585B2 (en) * | 2003-11-21 | 2006-07-04 | The Proctor & Gamble Company | Tampon having recessed portions |
| US20050113807A1 (en) * | 2003-11-21 | 2005-05-26 | The Procter & Gamble Company | Tampon with recessed portions |
| US7549982B2 (en) * | 2003-11-21 | 2009-06-23 | The Procter & Gamble Company | Tampon with recessed portions having multiple widths |
| US7097638B2 (en) * | 2003-11-21 | 2006-08-29 | The Procter & Gamble Company | Tampon having recessed portions |
| US7311699B2 (en) * | 2003-11-21 | 2007-12-25 | The Procter & Gamble Company | Tampon with raised portions |
| US7214218B2 (en) * | 2003-11-21 | 2007-05-08 | The Procter & Gamble Company | Tampon with raised portions having multiple widths |
| US7087045B2 (en) * | 2003-11-21 | 2006-08-08 | The Procter & Gamble Company | Tampon having recessed portions |
| US7338483B2 (en) | 2003-11-21 | 2008-03-04 | The Procter & Gamble Company | Tampon |
| US6939340B1 (en) | 2004-05-21 | 2005-09-06 | The Procter & Gamble Company | Tampon with adjacent wide and narrow raised portions |
| US7785308B2 (en) * | 2005-01-21 | 2010-08-31 | The Procter & Gamble Company | Tampon absorbency indicators on package |
| US20060167428A1 (en) * | 2005-01-21 | 2006-07-27 | Federica Denti | Tampon having indicators |
| US7175616B2 (en) * | 2005-01-21 | 2007-02-13 | The Procter & Gamble Company | Absorbency protuberance identifier disposed on each tampon in the article array |
| US7654991B2 (en) * | 2005-01-21 | 2010-02-02 | The Procter & Gamble Company | Product array having indicators |
| AU2007306534B2 (en) * | 2006-10-13 | 2012-10-25 | Cryovac, Inc. | Heat-resistant molded foam articles and process for their manufacture |
| JP5226689B2 (en) | 2006-11-08 | 2013-07-03 | プレイテックス プロダクツ エルエルシー | Tampon pledget with improved bypass leakage protection |
| US8062245B2 (en) * | 2007-02-08 | 2011-11-22 | The Procter & Gamble Company | Self-orienting applicator |
| JP5335773B2 (en) | 2007-05-17 | 2013-11-06 | プレイテックス プロダクツ エルエルシー | Tampump Ledget for enhanced prevention of bypass leaks |
| US8028385B2 (en) * | 2007-09-25 | 2011-10-04 | The Procter & Gamble Company | Patterned tampon and method of making |
| US20090281514A1 (en) | 2008-05-06 | 2009-11-12 | Playtex Products, Inc. | Tampon pledget with improved by-pass leakage protection |
| US9107775B2 (en) | 2009-04-15 | 2015-08-18 | Eveready Battery Company, Inc. | Tampon pledget with improved by-pass leakage protection |
| US20120330215A1 (en) * | 2011-06-24 | 2012-12-27 | Eva Grace Nellenbach | Method for moving articles and controlling the position of same |
| US20130263862A1 (en) | 2011-06-24 | 2013-10-10 | The Procter & Gamble Company | Method for moving articles and controlling the position of same |
| US10111786B2 (en) | 2015-04-10 | 2018-10-30 | First Quality Hygienic, Inc. | Tampon applicator including beveled portion |
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| US3765417A (en) * | 1971-02-24 | 1973-10-16 | Kimberly Clark Co | Arcuate tampon applicator |
| NO133929C (en) * | 1972-01-12 | 1976-07-28 | Rieber & Son Plastic Ind As | |
| US4368023A (en) * | 1979-06-22 | 1983-01-11 | Baxter Travenol Laboratories Inc. | Apparatus for making coude catheters |
| US4649012A (en) * | 1980-06-03 | 1987-03-10 | Maschinen Witte Kg | Method of shaping an elongated product |
| JP2561922B2 (en) * | 1986-04-23 | 1996-12-11 | キンバリ− クラ−ク コ−ポレ−シヨン | Tampon applicator |
| US5267953A (en) * | 1986-04-23 | 1993-12-07 | Kimberly-Clark Corporation | Curved tampon applicator and a process for forming the applicator and for assembling an absorbent tampon into said applicator |
| US5084038A (en) * | 1989-09-12 | 1992-01-28 | Kimberly-Clark Corporation | Apparatus and a method for forming tampons and the tampon itself |
| US5066212A (en) * | 1990-03-21 | 1991-11-19 | Midwest Plastic Fabricators | Apparatus for bending pipe |
| DE4109370A1 (en) * | 1990-05-23 | 1992-09-24 | Fraunhofer Ges Forschung | DEVICE FOR DEFORMING WORKPIECES FROM THERMOPLASTIC PLASTICS |
| US5153971A (en) * | 1991-11-26 | 1992-10-13 | Kimberly-Clark Corporation | Method of forming a curved tampon |
| CA2061606C (en) * | 1991-11-26 | 2002-09-17 | Thomas Peter Van Iten | A catamenial tampon |
| US5395308A (en) * | 1993-09-24 | 1995-03-07 | Kimberly-Clark Corporation | Thermoplastic applicator exhibiting accelerated breakup when immersed in water |
| US5407613A (en) * | 1993-11-09 | 1995-04-18 | Schulte; Franz | Process and apparatus for bending plastic pipe |
| US5437628A (en) * | 1993-11-10 | 1995-08-01 | Kimberly-Clark Corporation | Curved tampon applicator having an improved fingergrip |
-
1996
- 1996-07-09 CA CA002180789A patent/CA2180789C/en not_active Expired - Fee Related
-
1997
- 1997-07-19 US US08/899,491 patent/US5788910A/en not_active Expired - Lifetime
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2418928B (en) * | 2003-06-27 | 2007-01-10 | Playtex Products Inc | Tampon pledget having a shaped tip and method of making same |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2180789A1 (en) | 1997-01-12 |
| US5788910A (en) | 1998-08-04 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |