Playtex Products, Inc.

Thomas C McNelis

Jamshid Rejai

Michael L Miller

Robert C Norquest

Richard A Weber

There is provided a supporting rim structure of an open-ended tampon applicator for firmly supporting a tampon pledget that has been assembled in the applicator. The applicator supports the pledget around an intermediate section between its insertion end and its rear portion so that the insertion end is exposed outside of the applicator and the rear portion is inside of the applicator. In particular, the rim structure firmly supports the pledget against an axial force subjected to the pledget by a forming tool that forms the insertion end of the pledget into a rounded, hemispherical shape and yet readily allows the pledget to eject from the applicator. The rim structure has a shape that tapers angularly inward from the body of the applicator to form a rigid brace that counters the axial force subjected by the forming tool. Thus, while preventing the insertion end of the pledget from receding back into the applicator, the rim structure allows the pledget to easily eject from the applicator.

Supporting rim structure of an open insertion end tampon applicator used

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.

Post formed curved tampon assembly

There is provided a method for forming a round, hemispherical shape at the forward insertion end of a tampon pledget after the pledget has been assembled within a tampon applicator. The pledget is assembled within the applicator so that a portion of its fibers is exposed at an open insertion end of the applicator. After assembly, an insertion end formation tool is applied to the exposed fibers to form a depression in the middle of the insertion end and a full periphery cushion that flares peripherally outward from the depression. The insertion end formation tool has a reverse-donut shaped curvature with a central projection or spike. The central spike reduces the axial force necessary to form the full periphery cushion by radially displacing the fibers in the central location or middle of the insertion end of the pledget. With the insertion end formed in accordance with the method of present invention, the full periphery cushion provides a rounded, forward or insertion end to facilitate an application of the tampon for its intended use.

Growing community of inventors

Dover, DE, United States of America

Thomas C McNelis