Apparatus and method for manufacturing a tampon

An apparatus for manufacturing a tampon which includes an absorbent body, an accommodating member and a pushing member, includes: an orienting mechanism; a first inserting mechanism that inserts the pushing member into the accommodating member; and a second inserting mechanism that inserts the absorbent body into the accommodating member in which the pushing member is inserted. The orienting mechanism has an opening through which the accommodating member is inputted; a pair of first protruded parts; and a pair of second protruded parts located on other-end side in the longitudinal direction of the opening and protruding inwardly in an opposing manner into the opening, a gap between the pair of first protruded parts, and a gap between the pair of second protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part.

RELATED APPLICATIONS

The present application is a national phase of PCT/JP2009/062938, filed Jul. 17, 2009and is based on, and claims priority from, Japanese Application Number 2008-198349, filed Jul. 31, 2008, Japanese Application Number 2008-222213, filed Aug. 29, 2008, and Japanese Application Number 2008-251447, filed Sep. 29, 2008.

TECHNICAL FIELD

The present invention relates to an apparatus and method for manufacturing a tampon.

The present invention relates to a method and apparatus for manufacturing a tampon. Particularly, the present invention relates to a method and apparatus for manufacturing a tampon including a tampon main body, an accommodating cylinder accommodating the tampon main body, the accommodating cylinder having an opening formed at a leading end and a plurality of petaloid parts surrounding the opening, and a pushing member that is movable in the accommodating member and pushes the tampon main body out of the accommodating cylinder through the opening.

The present invention relates to an apparatus and method for manufacturing a tampon. Particularly, the present invention relates to an apparatus and method of manufacturing a tampon including a tampon main body, an accommodating cylinder that accommodates the tampon main body, and a pushing member that moves in the accommodating cylinder and pushes the tampon main body out of the accommodating cylinder, a plurality of petaloid parts being provided at a one-end part in the longitudinal direction of the accommodating cylinder.

BACKGROUND ART

A tampon (sanitary tampon) is known which is inserted into a vaginal cavity in the body and absorbs menstrual blood etc. Such a tampon includes, for example, an absorbent body that absorbs liquid such as menstrual blood, a cylindrical accommodating member that accommodates the absorbent body, and a pushing member that moves inside the accommodating member to push the absorbent body out of the accommodating member. A user of the tampon inserts into the vaginal cavity the accommodating member in which the absorbent body is accommodated and then pushes out the absorbent body using the pushing member. Thus, the absorbent body is guided into the vaginal cavity. Then, the absorbent body that is guided into the vaginal cavity absorbs menstrual blood etc., (see Patent Document 1).

A tampon including a tampon main body, an accommodating cylinder accommodating the tampon main body, the accommodating cylinder having an opening formed at a leading end and a plurality of petaloid parts surrounding the opening, and a pushing member that is movable in the accommodating member and pushes the tampon main body out of the accommodating cylinder through the opening is widely known as a sanitary product (for example, see Patent Document 1).

A tampon of the above structure is, for example, manufactured by fabricating each item constituting the tampon (i.e., a tampon main body, an accommodating cylinder and a pushing member) and inserting each of the pushing member and the tampon main body into the accommodating cylinder through the opening of the accommodating cylinder.

A tampon including a tampon main body, an accommodating cylinder that accommodates the tampon main body, and a pushing member that moves in the accommodating cylinder and pushes the tampon main body out of the accommodating cylinder, a plurality of petaloid parts being provided at a one-end part in the longitudinal direction of the accommodating cylinder is widely known as a sanitary product (for example, see Patent Document 1).

The above-mentioned tampon is manufactured by fabricating each of a tampon main body, an above-mentioned and a pushing member that constitutes a tampon and inserting the pushing member and the tampon main body into the accommodating cylinder. Further, a manufacturing apparatus of tampon may include a supplying mechanism that supplies the fabricated accommodating cylinder. The supplying mechanism includes a transport path that transports the accommodating cylinder. As the result of the transportation of the accommodating cylinder by the transport path, the accommodating cylinder is supplied to the predetermined supply destination.

Further, the transport path may include a first transport path that transports the accommodating cylinder in a first transport direction lying along the longitudinal direction of the accommodating cylinder; and a second transport path that receives from the first transport path the accommodating cylinder that has traveled on the first transport path and that transports the accommodating cylinder in a second transport direction intersecting the longitudinal direction of the accommodating cylinder. In such a case, the second transport path includes a receiving part that receives the accommodating cylinder from the first transport path. The accommodating cylinder that has traveled on the first transport path will travel on the second transport path after being received by the receiving part.

RELATED ART DOCUMENTS

Patent Document

DISCLOSURE OF INVENTION

Problems to be Solved by the Invention

When manufacturing a tampon of the above-mentioned structure, first, components of the tampon (an absorbent body, an accommodating member and a pushing member) are manufactured. Then, the manufactured components are respectively supplied to a transport conveyor etc., and the pushing member and the absorbent body are inserted into the accommodating member, so as to assemble the tampon. In order to assemble the tampon properly, it is necessary to supply each component to the transport conveyor with the component being oriented in a proper predetermined direction.

In consideration of the operability of the tampon, some type of the above-mentioned accommodating member may include a minor diameter part provided on one end thereof, and a major diameter part provided on the other end thereof and having an external diameter that is greater than that of the minor diameter part. With the accommodating member of such a structure, it is difficult to orient it in a predetermined direction and thus it is difficult to supply the accommodating member to the transport conveyor accurately and rapidly.

The present invention has been made in view of such a problem and its object is to supply the accommodating member accurately and rapidly while manufacturing a tampon.

In order to improve production speed of tampons, it is required to insert the tampon main body and the pushing member smoothly into the accommodating cylinder. However, there are cases where the plurality of petaloid parts provided on the accommodating cylinder is inclined inwardly in the radial direction of the accommodating cylinder due to causes such as impaction between accommodating cylinders. With the plurality of petaloid parts being inwardly inclined in the radial direction of the accommodating cylinder, the opening, which serves as an inserting inlet when inserting the tampon main body and the pushing member, is narrowed. Therefore, it will be difficult to insert the tampon main body and the pushing member into the accommodating cylinder.

The present invention has been made in view of such a problem and its object is to insert the tampon main body and the pushing member smoothly into the accommodating cylinder.

With above-mentioned structure, if the receiving part receives an accommodating cylinder and further receives an accommodating cylinder when the previous accommodating cylinder is already in the receiving part, there is a possibility that the accommodating cylinders will not be supplied properly. Specifically, if the receiving part receives an accommodating cylinder and further receives an accommodating cylinder when the previous accommodating cylinder is already in the receiving part, the accommodating cylinders will not fit into the second transport path.

In detail, if the receiving part tries to further receive accommodating cylinders with the previous accommodating cylinder being already in the receiving part, a plurality of accommodating cylinders will pile up before the receiving part (that is to say, the terminal end part of the first transport path). At this time, the accommodating cylinders piles up in a direction lying along the longitudinal direction of the accommodating cylinders. Regarding the accommodating cylinders which have piled up as has been described above, there may be an accommodating cylinder each of whose petaloid parts being inclined outwards, and the other accommodating cylinder (specifically, the other end part in the longitudinal direction of the other accommodating cylinder) may fit into such an accommodating cylinder. (For example, seeFIG. 45). In other words, if the plurality of accommodating cylinders piles up before the receiving part, the accommodating cylinders may join with each other. Under a situation where the accommodating cylinders are joined with each other, it will be difficult to supply the accommodating cylinders properly.

Accordingly, the present invention has been made in view of such a problem and its object is to supply the accommodating cylinders properly.

Means for Solving the Problems

In order to achieve the objects described above, the main aspect of the present invention is:

an apparatus for manufacturing a tampon, the tampon including an absorbent body that absorbs liquid, an accommodating member that is cylindrical and accommodates the absorbent body, and a pushing member that moves inside the accommodating member and pushes the absorbent body out of the accommodating member, the accommodating member including a minor diameter part provided at a one-end part thereof and a major diameter part provided at an other-end part thereof, the major diameter part having an external diameter greater than that of the minor diameter part, including:

an orienting mechanism that orients the accommodating member;

a first inserting mechanism that inserts the pushing member into the accommodating member oriented by the orienting mechanism; and

a second inserting mechanism that inserts the absorbent body into the accommodating member in which the pushing member is inserted,

the orienting mechanism including:

an opening through which the accommodating member is inputted;

a pair of first protruded parts located on one-end side in a longitudinal direction of the opening and protruding inwardly in an opposing manner into the opening; and

a pair of second protruded parts located on other-end side in the longitudinal direction of the opening and protruding inwardly in an opposing manner into the opening,

a gap between the pair of first protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part, and

a gap between the pair of second protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part.

In order to achieve the objects described above, the main aspect of the present invention is:

a method of manufacturing a tampon including a tampon main body, an accommodating cylinder accommodating the tampon main body, the accommodating cylinder having an opening formed at a leading end and a plurality of petaloid parts surrounding the opening, and a pushing member that is movable in the accommodating member and pushes the tampon main body out of the accommodating cylinder through the opening, including:

performing a broadening process on the accommodating cylinder, the broadening process broadens the opening by outwardly bending each of the plurality of petaloid parts in the radial direction of the accommodating cylinder;

after performing the broadening process, inserting the pushing member into the accommodating cylinder through the opening; and

after performing the broadening process, inserting the tampon main body into the accommodating cylinder through the opening.

In order to achieve the objects described above, the main aspect of the present invention is:

an apparatus for manufacturing a tampon including a tampon main body, an accommodating cylinder that accommodates the tampon main body, and a pushing member that moves in the accommodating cylinder and pushes the tampon main body out of the accommodating cylinder, a plurality of petaloid parts being provided at a one-end part in the longitudinal direction of the accommodating cylinder, comprising:

a supplying mechanism that supplies the accommodating cylinder; and

an inserting mechanism that inserts the tampon main body and the pushing member into the accommodating cylinder supplied by the supplying mechanism,

the supplying mechanism including:

a first transport path that transports the accommodating cylinder in a first transport direction lying along the longitudinal direction of the accommodating cylinder; and

a second transport path that transports the accommodating cylinder in a second transport direction intersecting the longitudinal direction of the accommodating cylinder,

the second transport path including:

a receiving part that receives from the first transport path the accommodating cylinder that has traveled on the first transport path;

a side wall formed on an end part opposite to a side where the accommodating cylinder is passed to the receiving part from the first transport path in the first transport direction; and

an outlet formed in the side wall and through which the accommodating cylinder is discharged from the second transport path,

the side wall retains in the receiving part the accommodating cylinder which the receiving part has received when there is no accommodating cylinder in the receiving part, and the accommodating cylinder which the receiving part has received when there is an accommodating cylinder in the receiving part is discharged from the second transport path through the outlet.

Other features of the present invention will become apparent from descriptions of this specification and of accompanying drawings.

Effect of the Invention

According to an aspect of the invention, the accommodating member can be supplied accurately and rapidly while manufacturing a tampon.

According to an aspect of the invention, the tampon main body and the pushing member can be smoothly inserted into the accommodating cylinder.

According to an aspect of the invention, the accommodating cylinders can be supplied properly.

At least the following matters will be disclosed in the present specification and accompanying drawings.

An apparatus for manufacturing a tampon, the tampon including an absorbent body that absorbs liquid, an accommodating member that is cylindrical and accommodates the absorbent body, and a pushing member that moves inside the accommodating member and pushes the absorbent body out of the accommodating member, the accommodating member including a minor diameter part provided at a one-end part thereof and a major diameter part provided at an other-end part thereof, the major diameter part having an external diameter greater than that of the minor diameter part, is provided, which includes:

an orienting mechanism that orients the accommodating member;

a first inserting mechanism that inserts the pushing member into the accommodating member oriented by the orienting mechanism; and

a second inserting mechanism that inserts the absorbent body into the accommodating member in which the pushing member is inserted,

the orienting mechanism including:

an opening through which the accommodating member is inputted;

a pair of first protruded parts located on one-end side in a longitudinal direction of the opening and protruding inwardly in an opposing manner into the opening; and

a pair of second protruded parts located on other-end side in the longitudinal direction of the opening and protruding inwardly in an opposing manner into the opening,

a gap between the pair of first protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part, and

a gap between the pair of second protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part.

With such an apparatus for manufacturing a tampon, since the above-mentioned relationship is established between the major diameter part, the minor diameter part, the gap between the first protruded parts and the gap between the second protruded parts, it becomes easier for the minor diameter part to pass through the opening before the major diameter part. As a result, the accommodating member is automatically oriented and thus the accommodating member can be supplied properly and rapidly.

In the above apparatus for manufacturing a tampon, it is preferable that, with respect to the accommodating member inputted into the opening in such a manner that a longitudinal direction of the accommodating member lies along the longitudinal direction of the opening,

one of the pair of first protruded parts and the pair of second protruded parts is provided at a position at which the minor diameter part passes between the pair of protruded parts; and

the other of the pair of first protruded parts and the pair of second protruded parts is provided at a position at which the major diameter part cannot pass between the pair of protruded parts.

With such an apparatus, since it can effectively prevent the major diameter part from passing through the opening before the minor diameter part, it is facilitated to orient the accommodating member properly.

In the above apparatus for manufacturing a tampon, it is preferable that, with respect to the accommodating member inputted into the opening in such a manner that the longitudinal direction of the accommodating member lies along the longitudinal direction of the opening,

the other of the pair of first protruded parts and the pair of second protruded parts is provided at a position where it comes into contact with a part of the accommodating member that is nearer to the center than the petaloid parts in the longitudinal direction.

With such an apparatus, the petaloid parts do not come into contact with the protruded parts. Therefore, for example, the petaloid parts can be prevented from being deformed and passing between the protruded parts (that is to say, the major diameter part can be prevented from passing between the protruded parts).

In the above apparatus for manufacturing a tampon, it is preferable that,

with respect to the accommodating member inputted into the opening in such a manner that the longitudinal direction of the accommodating member lies along the longitudinal direction of the opening,

the other of the pair of first protruded parts and the pair of second protruded parts is provided at a position where it comes into contact with a part of the accommodating member that is nearer to the petaloid parts than the center of the accommodating member in the longitudinal direction.

With such an apparatus, the part of the accommodating member that comes into contact with the other protruded parts when the accommodating member is inputted in the opening is at leading-end side of the major diameter part. (The accommodating member passes through the opening by rotating around this part). Therefore, thereafter, it becomes easier for the accommodating member to pass through the opening from the leading-end side of the minor diameter part that is on the opposite side. As a result, it becomes easier for the minor diameter part to surely pass through the opening before the major diameter part.

In the above apparatus for manufacturing a tampon, it is preferable that, the accommodating member includes an annular protrusion provided nearer to the end than the minor diameter part;

an external diameter of the annular protrusion being greater than the gap between the pair of first protruded parts and being greater than the gap between the pair of second protruded parts; and

with respect to the accommodating member inputted into the opening in such a manner that the longitudinal direction of the accommodating member lies along the longitudinal direction of the opening,

the one of the pair of first protruded parts and the pair of second protruded parts being provided at a position where it does not come into contact with the annular protrusion.

With such an apparatus, even though an annular protrusion is provided, by providing the protruded parts at positions where they do not come into contact with the annular protrusion, the annular protrusion will not be an obstruction when the minor diameter part passes between the protruded parts. Therefore, it is likely that the minor diameter part will be discharged prior to the major diameter part.

In the above apparatus for manufacturing a tampon, it is preferable that, the orienting mechanism includes:

a first jet part that is provided at a position opposing the first protruded parts and injects air towards the first protruded parts; and

a second jet part that is provided at a position opposing the second protruded parts and injects air towards the second protruded parts.

With such an apparatus, since the time taken for the accommodating member to pass through the opening will be shortened due to the air flow injected by the jet parts, the accommodating member can be supplied more rapidly.

In the above apparatus for manufacturing a tampon, it is preferable that, the apparatus includes:

a transport path that transports the accommodating member and inputs the accommodating member into the opening; and

the transport path inputs the accommodating member into the opening in such a manner that the attitude of the accommodating member, after being inputted, will be such that the major diameter part comes into contact with one of the pair of first protruded parts and the pair of second protruded parts.

With such an apparatus, since the accommodating member comes into contact with the protruded parts when inputted into the opening, even if the major diameter part is inputted into the opening prior to the major diameter part, the minor diameter part will be discharged prior to the major diameter part. Therefore, the accommodating member can be surely oriented.

In the above apparatus for manufacturing a tampon, it is preferable that, the opening is formed in a rectangular shape; and

a distance in the longitudinal direction between an edge on the one-end side in the longitudinal direction of the opening and the first protruded parts is equal to a distance in the longitudinal direction between an edge on the other-end side in the longitudinal direction of the opening and the second protruded parts.

As for the mode of inputting the accommodating member into the opening, there may be a case in which the major diameter part comes into contact with the first protruded parts and a case in which the major diameter part comes into contact with the second protrude parts. According to the apparatus described above, by providing the first protruded parts and the second protruded parts at an equal distance from the edge of the opening in the longitudinal direction, the accommodating member can be properly oriented in both cases.

Further, a method of manufacturing a tampon, the tampon including an absorbent body that absorbs liquid, an accommodating member that is cylindrical and accommodates the absorbent body, and a pushing member that moves inside the accommodating member and pushes the absorbent body out of the accommodating member, the accommodating member including a minor diameter part provided at a one-end part thereof and a major diameter part provided at an other-end part thereof, the major diameter part having an external diameter greater than that of the minor diameter part, is provided, which includes:

orienting, by an orienting mechanism, an orientation of the accommodating member; and

inserting, by an inserting mechanism, the absorbent body and the pushing member into the accommodating member that is oriented by the orienting mechanism,

the orienting mechanism including:

an opening through which the accommodating member is inputted;

a pair of first protruded parts protruding inwardly into the opening; and

a pair of second protruded parts protruding inwardly into the opening;

a gap between the pair of first protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part,

a gap between the pair of second protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part,

the orienting mechanism allowing the minor diameter part of the inputted accommodating member to pass through one of the pair of first protruded parts and the pair of second protruded parts, and not allowing the major diameter part of the inputted accommodating member to pass through the other of the pair of first protruded parts and the pair of second protruded parts, thereby discharging the minor diameter part of the accommodating member before the major diameter part of the accommodating member.

With such a method of manufacturing a tampon, since the minor diameter part is discharged from the opening prior to the major diameter part, the accommodating member is automatically oriented and thus the accommodating member can be supplied properly and rapidly.

—Structure of Tampon with Applicator—

Structure of a tampon with an applicator (hereinafter referred to as a tampon1001) will be described with reference toFIGS. 1A and 1B.FIG. 1Ais a partial cross-sectional diagram of the tampon1001with an inner cylinder1020being contracted.FIG. 1Bis a partial cross-sectional diagram of the tampon1001with an inner cylinder1020being extended. Regarding the longitudinal direction of the tampon1001shown in the drawings such asFIG. 1A, a side that is inserted into a vaginal cavity shall be referred to as a leading-end side and the opposite side shall be referred to as a rear-end side.

The tampon1001is a sanitary product including a tampon main body1004and an applicator1010.

The tampon main body1004includes an absorbent body1005and a cord1008. The absorbent body1005is a cotton body that blocks the vaginal cavity and absorbs liquid such as menstrual blood. The absorbent body1005is formed by cutting a cotton strip covered with non-woven fabric on both sides and heat forming into a substantially bullet like shape. The cord1008is sewn onto the absorbent body1005and extends from the rear-end side of the absorbent body1005. The cord1008is then held by a user when the absorbent body1005inside the vaginal cavity is pulled out of the vaginal cavity.

The applicator1010is an aid device for guiding the tampon main body1004(specifically, the absorbent body1005) into the vaginal cavity. The applicator1010includes an outer cylinder1011which is an example of an accommodating member that is cylindrical and accommodates the absorbent body1005and an inner cylinder1020which is an example of a pushing member that moves inside the outer cylinder1011and pushes the absorbent body1005out of the outer cylinder1011.

The outer cylinder1011is a cylindrical body formed by injection molding a thermoplastic resin and is flexible. The outer cylinder1011includes a minor diameter part1012provided at the rear-end part (one-end) and a major diameter part1013having an external diameter that is greater than that of a minor diameter part1012provided on the leading-end part (the other end). The minor diameter part1012is a grip part held by a user when using the tampon1001. The major diameter part1013is a part which has an internal diameter that is greater than the external diameter of the absorbent body1005and which accommodates the absorbent body1005therein. When using the tampon1001, the major diameter part1013is inserted into the vaginal cavity with the absorbent body1005being accommodated therein.

The outer cylinder1011(specifically, the major diameter part1013) includes a leading-end opening1014formed at its leading end and a plurality of petaloid parts1015surrounding the leading edge opening1014. When shipping the tampon1001, each of the plurality of petaloid parts1015is inwardly bent in an arc in the radial direction of the outer cylinder1011. Therefore, when the outer cylinder1011is inserted into the vaginal cavity, the leading-end part of the major diameter part1013is substantially hemispherical and the leading-end opening1014is substantially in a closed position.

Further, the outer cylinder1011includes a rear-end opening1016formed at its rear end (seeFIG. 3A) and an annular protrusion (annular rib)1017provided at a position slightly towards the leading-end side than the rear-end opening1016(provided at a position nearer to the rear-end side than the minor diameter part1012). Further, an annular stepped part1018is formed between the minor diameter part1012and the major diameter part1013.

The inner cylinder1020is a cylindrical body inserted in the minor diameter part1012. The inner cylinder1020is provided at a position nearer to the rear-end side than the absorbent body1005accommodated in the major diameter part1013and pushes the absorbent body1005from the rear towards the leading-end opening1014. Thereby, the absorbent body1005(tampon main body1004) pushes out each of the plurality of petaloid parts1015outwardly in the radial direction of the outer cylinder1011and is pushed out of the major diameter part1013. The cord1008extends through the inner cylinder1020and is pulled out from the opening at the rear-end side of the inner cylinder1020. It is to be noted that the inner cylinder1020of the present embodiment is formed as an extendable two-tier structure. In detail, the inner cylinder1020includes a first inner cylinder1021and a second inner cylinder1025that is slidably inserted in the first inner cylinder.

The first inner cylinder1021has an external diameter that is smaller than the internal diameter of the minor diameter part1012and is inserted in the minor diameter part1012. An annular flange part1022is formed on an outer peripheral surface of the leading-end part of the first inner cylinder1021. The flange part1022has an external diameter that is smaller than the internal diameter of the major diameter part1013(greater than the internal diameter of the minor diameter part1012) and engages an inner surface of the stepped part1018of the outer cylinder1011, thereby preventing the inner cylinder1020from falling off from the rear-end opening1016of the outer cylinder1011. Further, at the rear-end side on an inner peripheral surface of the first inner cylinder1021, an annular protrusion1023extending inwardly in the radial direction is provided.

The second inner cylinder1025has an external diameter that is smaller than the internal diameter of the first inner cylinder1021. The second inner cylinder1025is, when the inner cylinder1020is in a contracted state, inserted in the first inner cylinder1021as shown inFIG. 1Aand, when the inner cylinder1020is in an extended state, connected to the rear-end part of the first inner cylinder1021at the leading-end part of the second inner cylinder1025as shown inFIG. 1B. Further, on the outer peripheral surface of the leading-end part of the second inner cylinder1025, an arcuate flange part1026and a protruded part1027provided at a position nearer to the rear-end side than the flange part1026is formed. When the annular protrusion1023of the first inner cylinder1021is at a position between the flange part1026and the protruded part1027as shown inFIG. 1B, the protrusion1023engages the flange part1026and the protruded part1027, and thus the first inner cylinder1021and the second inner cylinder1025are connected. Further, a flared part1028is formed at the rear-end part of the second inner cylinder1025. The external diameter of the flared part1028is greater than the internal diameter of the first inner cylinder1021.

—Method of Manufacturing a Tampon1001—

FIG. 2Ais a flowchart showing how the tampon1001is manufactured.FIG. 2Bis a diagram showing details of the assembling step.FIGS. 3A to 3Dare diagrams showing the assembling step of the tampon1001in a series. In the following description, the method of manufacturing the tampon1001will be described step by step (steps S1010, S1020, S1030, S1040and S1050).

<<Manufacturing Step of Tampon Main Body1004: STEP S1010>>

First, a cotton strip is covered with non-woven fiber on both surfaces and then the cotton strip is cut. Secondly, a cord is sewn on the cut cotton strip using a sewing thread. Then, the cotton strip on which the cord is sewn is pressed into a substantially bullet-shaped cotton body and then heat formed. In this manner, the tampon main body1004having the absorbent body1005and the cord1008is manufactured.

Using an injection molding machine, the outer cylinder1011and the inner cylinder1020(the first inner cylinder1021and the second inner cylinder1025) are each injection molded. The outer cylinder1011is injection molded using a thermoplastic resin, for example. It is to be noted that at the time of manufacture, the outer cylinder1011is in a state where each of the plurality of petaloid parts1015is open, i.e., a leading-end opening1014is in an open state (SeeFIG. 3A). Also, the flared part1028is not formed at the rear-end part of the second inner cylinder1025(SeeFIG. 3B).

The manufactured tampon main body1004, the outer cylinder1011and the inner cylinder1020(the first inner cylinder1021and the second inner cylinder1025) are assembled by an assembling apparatus1040(details will be described later), which is an example of the manufacturing apparatus of the tampon1001.

An outline of the assembling of the tampon1001will be described.

First, in the assembling apparatus1040, the outer cylinder1011is supplied to a transport conveyor (step S1031). The outer cylinder1011that is being supplied is oriented (step S1032). Then, as shown inFIG. 3A, the first inner cylinder1021is inserted into the oriented outer cylinder1011(step S1033). It is to be noted that the first inner cylinder1021is inserted into the outer cylinder1011through the leading-end opening1014thereof. Then, as shown inFIG. 3B, the second inner cylinder1025is inserted into the outer cylinder1011in which the first inner cylinder1021is inserted (step S1034). In this manner, the applicator1020is assembled. Then, as shown inFIG. 3C, the tampon main body1004is inserted into the outer cylinder1011(step1035). In this step, the cord1008is firstly inserted into the outer cylinder1011. Thereby, the absorbent body1005is accommodated in the major diameter part1013.

It is to be noted that in this assembling step, step S1032corresponds to the step of orienting the outer cylinder1011by the orienting mechanism1060(to be described later) and steps S1033to S1035correspond to the steps of inserting the absorbent body1005and the inner cylinder1020into the outer cylinder1011which has been oriented by the orienting mechanism1060by the tampon main body inserting part1070(to be described later).

The structure of the assembling apparatus1040that assembles the tampon1001will now be described.FIG. 4is a diagram showing the assembling apparatus1040of the tampon1001.

The assembling apparatus1040includes an outer cylinder supplying part1041, a transport conveyor1050, a first inner cylinder supplying part1051, a second inner cylinder supplying part1052and a tampon main body inserting part1070.

The transport conveyor1050transports the outer cylinder1011and each article (the first inner cylinder1021, the second inner cylinder1025and the tampon main body1004) inserted in the outer cylinder1011in a transport direction. A fixing table (not shown) adapted to fix the outer cylinder1011is provided on the transport conveyor1050. As the fixing table is transported by the transport conveyor1050, the outer cylinder1011etc., that is fixed on the fixing table is transported in the transport direction.

The outer cylinder supplying part1041supplies the outer cylinder1011to the transport conveyor1050. The outer cylinder supplying part1041includes an outer cylinder transport feeder1042and a transport path1043on which the supplied outer cylinders1011are transported.

The outer cylinder transport feeder1042is a parts feeder having a bowl-shaped vibratory table1042a. By vibrating the vibratory table1042a, the outer cylinder transport feeder1042transports the outer cylinder1011to the transport path1043.

At a middle part and an end part of the transport path1043, accumulating parts1044and1046are formed that accumulate the outer cylinders1011which are being transported primarily in a side-by-side manner. The plurality of outer cylinders1011accumulated in the accumulating parts1044and1046are arranged in a side-by-side manner. Between the accumulating parts1044and1046, there is provided a drop chute1045through which the outer cylinders1011drop. At the end of the transport path1043, an outer cylinder setting part (not shown) that sets the outer cylinder1011accumulated in the accumulating part1046on the fixing table of the transport conveyor1050is provided. At the inlet of the drop chute1045, an orienting mechanism1060(details will be described later) that orients the outer cylinder1011that is inputted into the drop chute1045is provided.

With the outer cylinder supplying part1041of such structure, the outer cylinders1011transported on the transport path1043and accumulated in the accumulating part1044drop through the drop chute1045sequentially. (During this, the outer cylinders1011are oriented). Then, the outer cylinders1011that have passed through the drop chute1045are accumulated in the accumulating part1046. Then, the outer cylinders1011accumulated in the accumulating part1046are set on the fixing table of the transport conveyor1050by the outer cylinder setting part.

The first inner cylinder supplying part1051supplies the first inner cylinder1021to the transport conveyor1050, which first inner cylinder1021is to be inserted into the outer cylinder1011transported by the transport conveyor1050. The first inner cylinder supplying part1051includes an inner cylinder transport feeder1053and a transport tube1054.

The inner cylinder transport feeder1053is a parts feeder having a bowl-shaped vibratory table1053a. A pair of rails1055forming a part of the transport path of the first inner cylinder1021is attached to the inner cylinder transport feeder1053. Between the pair of rails1055, a space that can hold the first inner cylinder1021between the rails1055is formed. The flange part1022of the first inner cylinder1021held in the space engages the top part of the pair of rails1055and the first inner cylinder1021is transported while being hung down from the pair of rails1055.

The first inner cylinder1021transported by the pair of rails1055drops in the transport tube1054with its leading end being located above the rear end. At the end of the transport tube1054, an inner cylinder inserting mechanism (not shown) that inserts The first inner cylinder1021into the outer cylinder1011is provided. When the outer cylinder1011that is being transported by the transport conveyor1050is located below the inner cylinder inserting mechanism, the inner cylinder inserting mechanism presses the first inner cylinder1021dropped in the transport tube1054and inserts it into the outer cylinder1011. In other words, the first inner cylinder1021is inserted into the outer cylinder1011as shown inFIG. 3A. It is to be noted that the transport tube1054and the inner cylinder inserting mechanism correspond to the first inserting mechanism.

The second inner cylinder supplying part1052supplies the second inner cylinder1025to the transport conveyor1050, which second inner cylinder1025is to be inserted into the outer cylinder1011that is being transported with the first inner cylinder1021inserted therein. Since the structure of the second inner cylinder supplying part1052is similar to that of the first inner cylinder supplying part1051, it will not be described here. As shown inFIG. 3B, the second inner cylinder1025is inserted into the outer cylinder1011by the second inner cylinder supplying part1052.

The tampon main body inserting part1070(an example of the second inserting mechanism) inserts the absorbent body1005(tampon main body1004) into the outer cylinder1011in which the first inner cylinder1021and the second inner cylinder1025are inserted. The tampon main body inserting part1070includes a guide part1071that guides the insertion of the tampon main body1004into the outer cylinder1011and a pin72that pushes the tampon main body1004out of the guide part1071. The guide part1071further includes a mechanism that holds the tampon main body1004. The tampon main body1004in the guide part1071is held in a state that the cord1008is situated below the absorbent body1005.

When the outer cylinder1011that is being transported by the transport conveyor1050is situated below the guide part1071, the tampon main body inserting part1070pushes the tampon main body1004held by the guide part1071using the pin1072. Thereby, as shown inFIG. 3C, the tampon main body1004is inserted into the outer cylinder1011.

By performing the assembling step (step S1030) with the assembling apparatus1040of the above-mentioned structure, the first inner cylinder1021, the second inner cylinder1025and the tampon main body1004are properly inserted into the outer cylinder1011.

In this processing step, a bending process for arcuately bending the petaloid parts1015in the open state of the outer cylinder1011inwardly in the radial direction of the outer cylinder1011is performed. It is to be noted that the process of forming the flared part1028at the rear-end part of the second inner cylinder1025is performed in the assembling step (step S1030). With these processes, the tampon1001shown inFIG. 3Dis formed.

With the processing of the tampon1001is completed, the tampon1001is inserted into a wrapper that is formed into a cylindrical shape to wrap the tampon1001. Thereafter, a plurality of wrapped tampons1001are packed in a box. Thus, the manufacturing of the tampons1001is completed and they will be shipped later on.

—Detailed Structure of Orienting Mechanism1060—

FIG. 5is a perspective diagram showing an orienting mechanism1060and the neighboring part thereof.FIG. 6is a top view showing an orienting plate1061.FIGS. 7A and 7Bare diagrams showing a positional relationship between the outer cylinder1011and an orienting plate1061when the outer cylinder1011is being dropped into an opening1062.

As shown inFIG. 5, the orienting mechanism1060is provided at the inlet of the drop chute1045and includes the orienting plate1061, a first jet part1067and a second jet part1068. In the following description, after describing the structure of the orienting plate1061, the structures of a first jet part1067and a second jet part1068will be described.

<<Structure of the Orienting Plate1061>>

The orienting plate1061is a rectangular flat plate provided at the inlet of the drop chute1045. The outer cylinders1011accumulated side-by-side in the accumulating part1044are dropped through the orienting plate1061and the outer cylinders1011are oriented.

As shown inFIG. 6, the orienting plate1061includes an opening1062through which the outer cylinder1011is inputted and first protruded parts1063and second protrude parts1064protruding inwardly into the opening1062.

The opening1062is a rectangular opening and is formed in such a manner that its size is slightly greater that the size of the outer cylinder1011. The outer cylinders1011that are transported on the transport path1043and accumulated in the accumulating part1044are inputted into the opening1062sequentially. As shown inFIGS. 7A and 7B, the outer cylinder1011is inputted in such a manner that the longitudinal direction of the outer cylinder1011lies along the longitudinal direction of the opening1062. For example, among the outer cylinders1011accumulated in the accumulating part1044shown inFIG. 5, the outer cylinder1011that is at the nearest position to the opening1062is inputted as shown inFIG. 7Aand the outer cylinder1011that is at the second nearest position to the opening1062is inputted as shown inFIG. 7B.

The first protruded parts1063are provided at one end side in the longitudinal direction of the opening1062and are a pair of opposing protruded parts. As shown inFIGS. 7A and 7B, the gap between the pair of the first protruded part1063is greater than the external diameter of the minor diameter part1012of the outer cylinder1011and is smaller than the external diameter of the major diameter part1013. Further, the external diameter of the annular protrusion1017of the outer cylinder1011is greater than a gap between a pair of first protruded parts1063. Therefore, the major diameter part1013and the annular protrusion1017cannot pass through the pair of first protruded part1063and on the other hand the minor diameter part1012can pass through the pair of first protruded part1063.

The second protruded parts1064are provided at the other end side in the longitudinal direction of the opening1062and are a pair of opposing protruded parts. Similarly to the first protruded part1063, the gap between a pair of the second protruded parts1064is greater than the external diameter of the minor diameter part1012of the outer cylinder1011and is smaller than the external diameter of the major diameter part1013. Further, the external diameter of the annular protrusion1017of the outer cylinder1011is greater than a gap between a pair of first protruded parts1063. Therefore, the major diameter part1013and the annular protrusion1017cannot pass through the pair of first protruded parts1063and on the other hand the minor diameter part1012can pass through the pair of first protruded part1063.

The opening1062is divided into three portions by the first protruded parts1063and the second protruded parts1064. (In other words, it is divided into a one-end opening1062a, a central opening1062band other-end opening1062c.) The one-end opening1062ais at a location nearer to the one-end side in the longitudinal direction of the opening than the first protruded parts1063, the central opening1062bis at a location between the first protruded parts1063and the second protruded parts1064in the longitudinal direction, and the other end opening1062cis at a position nearer to the other end side than the second protruded part1064in the longitudinal direction. The width in the longitudinal direction of the one end opening1062aand the width in longitudinal direction of the other end opening1062care smaller than the external diameter of the minor diameter part1012. On the other hand, the width in longitudinal direction of the central opening1062bis greater than the external diameter of the major diameter part1013. The width in longitudinal direction of the one end opening1062a(in other words, the distance between the edge on the one end side of the longitudinal direction of the first end opening1062aand the first protruded parts1063) is the same as the width in the longitudinal direction of the other end opening1062c(in other words, the distant between an edge on The opening1062other end part in the longitudinal direction and the second protruded parts1064).

The positional relationship between the outer cylinder1011inputted into the opening1062and the first and second protruded parts1063,1064will now be described.

First, a case in which the outer cylinder1011is inputted as shown inFIG. 7Awill be described. With regards to the outer cylinder1011inputted into the opening1062, among the first protruded parts1063and the second protruded parts1064, the second protruded parts1064are provided at positions where they do not come into contact with the annular protrusion1017(specifically, at positions nearer to the center than the annular protrusion1017in the longitudinal direction of the opening1062.) On the other hand, the first protruded parts1063are provided at positions where they come into contact with a part of the outer cylinder1011which is nearer to the center than the petaloid parts1015in the longitudinal direction (specifically, at a part of the outer cylinder1011nearer to the petaloid parts1015than the center). Accordingly, the second protruded parts1064are provided at positions where the minor diameter part1012passes between the pair of second protruded parts1064and the first protruded parts1063are provided at positions where the major diameter part1013cannot pass between the pair of first protruded parts1063.

Secondly, a case in which the outer cylinder1011is inputted as shown inFIG. 7Bis described. With regards to the outer cylinder1011inputted into the opening1062, among the first protruded parts1063and the second protruded parts1064, the first protruded parts1063are provided at positions where they do not come into contact with the annular protrusion1017(specifically, at positions nearer to the center than the annular protrusion1017in the longitudinal direction of the opening1062.) On the other hand, the second protruded parts1064are provided at positions where they come into contact with a part of the outer cylinder1011which is nearer to the center than the petaloid parts1015in the longitudinal direction (specifically, at a part of the outer cylinder1011nearer to the petaloid parts1015than the center). Accordingly, the first protruded parts1063are provided at positions where the minor diameter part1012passes between the pair of first protruded parts1063and the second protruded parts1064are provided at positions where the major diameter part1013cannot pass between the pair of second protruded parts1064.

By providing the orienting plate1061of such a structure, the orientation of the outer cylinder1011inputted into the opening1062is properly and quickly oriented based on the mechanism of orienting the outer cylinder1011to be described later.

<<Structure of First Jet Part1067and Second Jet Part1068>>

As shown inFIG. 5, a first jet part1067is provided at a position above the orienting plate1061and opposing the first protruded parts1063. Further, the first jet part1067includes a nozzle1067athat injects air and injects air towards the first protruded parts1063. In other words, the first jet part1067injects air towards the outer cylinder1011inputted into the opening1062(in the case ofFIG. 7A, towards the major diameter part1013).

The second jet part1068is provided at a position above the orienting plate1061and opposing the second protruded parts1064. Further, the second jet part1068includes a nozzle1068athat injects air and injects the air towards the second protruded parts1064. In other words, the second jet part1068injects the air towards the outer cylinder1011inputted into the opening1062(in the case ofFIG. 7A, towards the minor diameter part1012).

Because the first jet part1067and the second jet part1068inject air towards the outer cylinder1011inputted into the opening1062, the time taken for the outer cylinder1011to pass through the opening1062(drop chute1045) can be shortened and the supply speed of the outer cylinder1011can be increased. It is to be noted that during the supply of outer cylinder1011, the first jet part1067and the second jet part1068inject air continuously. Of course, air can be intermittently injected in accordance with the dropping timing of the outer cylinder1011into the opening1062.

—Mechanism of Orienting the Outer Cylinder1011Using the Orienting Mechanism1060—

As has been described above, the outer cylinder1011is inputted into the opening1062with one of the two modes shown inFIGS. 7A and 7B. Since the mechanism for orienting the outer cylinder1011inputted as shown inFIG. 7Aand the mechanism for orienting the outer cylinder1011inputted as shown inFIG. 7Bare similar, the following description will be made with reference to the mechanism of orienting the outer cylinder1011that is inputted as shown inFIG. 7A.

FIGS. 8A to 8Dare diagrams illustrating the mechanism of orienting the outer cylinder1011.

FIG. 8Ashows how the outer cylinder1011accumulated side-by-side in the accumulating part1044is inputted into the opening1062in the orienting plate1061in a state shortly before the outer cylinder1011is inputted into the opening1062. The outer cylinder1011is inputted into the opening1062with an attitude such that the major diameter part1013comes into contact with the pair of first protruded parts1063after being inputted. In detail, the outer cylinder1011is inputted in such a manner that the outer cylinder1011and the opening1062are in parallel. Therefore, since the minor diameter part1012and the major diameter part1013of the outer cylinder1011are inputted into the opening1062substantially at the same time, the subsequent orienting can be performed properly.

The major diameter part1013of the outer cylinder1011that is inputted comes into contact with the first protruded parts1063as shown inFIG. 8B, since the external diameter of the major diameter part1013is greater than the gap between the pair of first protruded parts1063. In other words, the major diameter part1013does not pass between the first protruded parts1063. It is to be noted that because the first protruded parts1063come into contact with a part of the major diameter part1013nearer to the center than the petaloid parts1015in the longitudinal direction, the petaloid parts1015can be prevented from being deformed by coming into contact with the first protruded parts1063and passing between the first protruded parts1063.

On the other hand, since the external diameter of the minor diameter part1012is smaller than the gap between the pair of second protruded parts1064, the minor diameter part1012of the outer cylinder1011starts passing between the pair of second protruded parts1064as shown inFIG. 8B. It is to be noted that because the first protruded parts1063come into contact with a part of the outer cylinder1011nearer to the petaloid parts1015than the center, it is likely to drop from the leading-end side of the minor diameter part1012on the opposite side. As a result, it is easier for the minor diameter part1012to pass between the second protruded parts1064.

Also, when the minor diameter part1012passes between the second protruded parts1064, the annular protrusion1017of the outer cylinder1011starts passing the other-end opening1062c. That is to say, the annular protrusion1017does not obstruct the passage of the minor diameter part1012through the opening1062because the annular protrusion1017is at a position that does not come into contact with the second protruded parts1064. Further, since the second jet part1068opposing the second protruded parts1064injects air towards the minor diameter part1012, the speed at which the minor diameter part1012passes between the pair of second protruded parts1064increases.

Also after the minor diameter part1012has started passing between the second protruded parts1064, while major diameter part1013remains in contact with the first protruded parts1063(i.e., a state in which the major diameter part1013does not pass between the pair of first protruded parts1063), the minor diameter part1012drops between the pair of second protruded parts1064(the minor diameter part1012rotates about a part at which the major diameter part1013is in contact with the first protruded parts1063). Thus, the minor diameter part1012completely passes between the pair of second protruded parts1064as shown inFIG. 8C. At this point, the major diameter part1013starts passing through the central opening1062b.

In this manner, the major diameter part1013completely passes through the central opening1062cand the outer cylinder1011is discharged from the orienting plate1061as shown inFIG. 8D. The plurality of outer cylinders1011accumulated side-by-side in the accumulating part1044are sequentially inputted into the opening1062and each of the outer cylinders1011discharged from the opening1062is oriented in a manner described below. That is to say, as shown inFIG. 8D, the outer cylinder1011is oriented in such a manner that its major diameter part1013is at an upper position and the minor diameter part1012is at a lower position. (In other words, it is oriented in such a manner that the minor diameter part1012drops first).

It is to be noted that also for the outer cylinder1011that is dropped in a manner shown inFIG. 7B, the outer cylinder1011is oriented by a similar mechanism. That is to say, the outer cylinder1011is oriented in such a manner that the minor diameter part1012drops first.

In this manner, the orienting mechanism1060discharges the minor diameter part1012of the outer cylinder1011prior to the major diameter part1013by allowing the minor diameter part1012of the outer cylinder1011that has been inputted to pass between one of the pair of first protruded parts1063and the pair of the second protruded parts1064while not allowing the major diameter part1013of the outer cylinder1011that has been inputted to pass between the other of the pair of first protruded parts1063and the pair of the second protruded parts1064.

<<Effectiveness of Assembling Apparatus1040and Manufacturing Method of the Present Embodiment>>

As has been described above and as shown inFIG. 5, the orienting mechanism1060includes the opening1062through which the outer cylinder1011is inputted, the pair of first protruded parts1063and the pair of second protruded parts1064protruding inwardly into the opening1062. The gap between the pair of first protruded parts1063and the gap between the pair of second protruded parts1064are each greater than the external diameter of the minor diameter part1012of the outer cylinder1011and smaller than the external diameter of the major diameter part1013. Thus, the outer cylinder1011can be supplied properly and rapidly when manufacturing the tampon1001.

In the following description, the effectiveness of the present embodiment will be described with reference to two comparison examples.

Firstly, in comparison example 1, the orientation of the outer cylinder1011that is being transported in the transport path is determined based on video signals obtained by imaging the outer cylinder1011using camera etc., having an image sensor. Then, the outer cylinder1011is oriented by using a turning device to change the orientation in such a manner that the outer cylinder1011is oriented in a predetermined orientation. However, in the case of comparison example 1, a complicated structure is required and it is likely that a longer time will be needed to orient the outer cylinder1011.

In comparison example 2, the outer cylinder1011is sent to a device which fits with the major diameter part1013but does not fit with the minor diameter part1012. Then, the outer cylinder1011is oriented by discharging only the outer cylinder1011that was sent in the orientation which does not fit. However, in the case of comparison example 2, since the major diameter part1013includes the petaloid parts1015, it is difficult to fit the major diameter part1013in a proper manner. As a result, there is a possibility that the outer cylinder1011is falsely discharged. Also, since the outer cylinder1011is discharged, the supply efficiency of the outer cylinder1011is decreased.

On the other hand, in the present embodiment, since the above-mentioned relationship holds between the external diameter of the minor diameter part1012, the external diameter of the major diameter part1013, the gap between the first protruded parts1063and the gap between the second protruded parts1064, it is easier for the minor diameter part1012to firstly pass through the gaps between one of the first protruded parts1063and the second protruded parts1064. Specifically, as shown inFIGS. 8A to 8D, for example, the orienting mechanism1060allows the minor diameter part1012of the outer cylinder1011that has been inputted to pass between the pair of second protruded parts1064and does not allow the major diameter part1013to pass between the pair of first protruded parts1063. Accordingly, the minor diameter part1012of the outer cylinder1011is discharged prior to the major diameter part1013. Thus, the outer cylinder1011that drops in the drop chute45simply passes through the orienting plate1061and then the outer cylinder1011is oriented automatically. As a result, the outer cylinder1011can be supplied rapidly as compared to comparison example 1. Also, the structure can be simplified as compared to comparison example 1. Further, since the orientation of all outer cylinders1011that drops into the drop chute1045can be oriented, the supply efficiency can be raised as compared to comparison example 2.

Based on the above, according to the assembling apparatus1040and manufacturing method of the tampon1001of the present embodiment, upon manufacturing the tampon1001, the outer cylinder1011can be supplied to the transport conveyor1050properly and rapidly.

A second embodiment that has a different structure from the above-described embodiment (first embodiment) will now be described. In the following description, the structure of a tampon1001of the second embodiment and the manufacturing method and assembling apparatus1040of the above-mentioned tampon1001will be described. It is to be noted that the structure whose description is omitted is similar to that of the first embodiment.

FIG. 9Ais a cross-sectional view of a tampon1001of the second embodiment.FIG. 9Bis an elevation view of an outer cylinder1011. The tampon1001of the second embodiment has an external diameter smaller than that of the tampon1001of the first embodiment (FIG. 1A) and is designed to achieve an easier insertion into a vaginal cavity.

As shown inFIG. 9A, the tampon1001includes a tampon main body1004and an applicator1010. The tampon main body1004has a structure that is similar to the tampon main body1004shown inFIG. 1Aand includes an absorbent body1005and a cord1008.

The applicator1010includes an outer cylinder1011and an inner cylinder1020. As shown inFIG. 9B, the outer cylinder1011includes a minor diameter part1012and a major diameter part1013. In a manner similar to the outer cylinder1011shown inFIG. 1A, the major diameter part1013includes a leading-end opening1014formed at the leading end and a plurality of petaloid parts1015surrounding the leading-end opening. On the other hand, the minor diameter part1012does not include an annular protrusion1017(FIG. 1A) formed thereon. The inner cylinder1020differs from the inner cylinder1020shown inFIG. 1A(the inner cylinder1020having the first inner cylinder1021and the second inner cylinder1025) and includes a single inner cylinder only.

The tampon1001of the above-mentioned structure is also manufactured in accordance with the manufacture flowchart shown inFIGS. 2A and 2B. However, since there is only one inner cylinder1020, manufacturing is simplified as compared to the first embodiment. Also, when supplying the outer cylinder1011at the assembling apparatus1040, the outer cylinder1011is oriented by the orienting mechanism1060. The orienting mechanism1060of the second embodiment has a structure different from that of the first embodiment (FIG. 5). Therefore, in the following description, the structure of the orienting mechanism1060will be described.

FIG. 10is a diagram showing a drop chute1045of the second embodiment and the neighboring part thereof.FIG. 11Ais a partial cross-sectional view of the drop chute1045viewed in Y-direction in FIG.10.FIG. 11Bis a cross-sectional view taken along line X-X inFIG. 10.

The drop chute1045does not include an orienting plate1061shown inFIG. 5. In stead, the first protruded parts1063and the second protruded parts1064are formed by pins protruding from a frame1045aof the drop chute1045. The first protruded parts1063and the second protruded parts1064are provided at the same level in a vertical direction. In the dropping path of the outer cylinder1011in the drop chute1045, an opening1062corresponding to a plane passing through the first protruded parts1063and the second protruded parts1064is equivalent to the above-mentioned opening1062. In a similar manner to the opening1062shown inFIG. 6, the opening1062is divided into a one-end opening1062a, a central opening1062band an other-end opening1062c(seeFIG. 11B).

As shown inFIG. 11A, in the path of the drop chute1045, a bent part1084is formed above the first protruded parts1063and the second protruded parts1064. The outer cylinder1011that has proceeded into the drop chute1045(for example, the outer cylinder1011that has proceeded at an angle into the drop chute1045) passes the bent part1084and thereby takes an attitude lying along the horizontal direction. Therefore, the minor diameter part1012and the major diameter part1013will be inputted into the opening1062at substantially the same time.

Two pairs of transport rollers1081and1082are provided on the transport path1043at the upstream side of the drop chute1045in the transport direction. The transport rollers1081and1082are pairs of rollers respectively that transport the outer cylinder1011while holding the outer cylinder1011between them. The outer cylinders1011transported through the transport path1043are arranged side-by-side and moves to the transport rollers1081and1082. Here, the rotational speed of the transport rollers1082is greater than the rotational speed of the transport rollers1081. Therefore, even if two outer cylinders1011that are supplied consecutively happen to join (for example, when the petaloid parts1015of the two consecutively supplied outer cylinders1011are in meshing engagement), the two outer cylinders1011can be separated by the transport rollers1081and1082and the outer cylinder1011can proceed into the drop chute1045one-by-one.

The orientation of the outer cylinder1011dropping in the drop chute1045of the above structure can be oriented in a manner described below.

As shown inFIG. 11B, when the outer cylinder1011is inputted into the opening1062, since the external diameter of the major diameter part1013is greater than the gap between the first protruded parts1063, the major diameter part1013comes into contact with the pair of first protruded parts1063and thus the major diameter part1013cannot pass between the pair of first protruded parts1063. On the other hand, since the external diameter of the minor diameter part1012is smaller than the gap between the second protruded parts1064, the minor diameter part1012starts passing between the pair of second protruded parts1064. Thereafter, as shown inFIG. 10, with the major diameter part1013being in contact with the first protruded parts1063, the minor diameter part1012completely passes between the second protruded parts1064. Then, the major diameter part1013passes through the central opening1062bto discharge the outer cylinder1011from the opening1062(that is to say, the minor diameter part1012is discharged first). In this manner, the outer cylinder1011is oriented in such a manner that its major diameter part1013is at an upper position and its minor diameter part1012is at a lower position.

It is to be noted that even if the outer cylinder1011is inputted in such a manner that the major diameter part1013comes into contact with the second protruded parts1064, because the minor diameter part1012is discharged first, the outer cylinder1011will be oriented.

In this manner, also in the second embodiment, the outer cylinder1011can be supplied to the transport conveyor1050properly and rapidly because of the orienting mechanism1060.

In the above-mentioned various embodiments, the manufacturing apparatus and the method of manufacturing the tampon of the present invention have been mainly discussed. However, the above-mentioned embodiments are provided for the purpose of facilitating the understanding of the present invention only and do not give any limitation to the present invention. It goes without saying that any modifications and improvements to the present invention can be made without departing from the spirit of the invention and the present invention includes its equivalents. Further, the above-mentioned configurations, etc., are merely examples to show effectiveness of the present invention and should not be understood as any limitation to the present invention.

In the above-mentioned embodiments, the inner cylinder1020of the tampon1001shown inFIG. 1Aincludes the first inner cylinder1021and the second inner cylinder1025. However, the inner cylinder1020may include the first inner cylinder1021only.

Also, in the above-mentioned embodiments, the outer cylinder1011is oriented by dropping the outer cylinder1011shown inFIG. 9onto the drop chute1045shown inFIG. 10, however, it is not limited thereto.

For example, the outer cylinder1011may be oriented by dropping the outer cylinder1011shown inFIG. 3Aonto the drop chute1045shown inFIG. 10.

First, a method of manufacturing a tampon including a tampon main body, an accommodating cylinder accommodating the tampon main body, the accommodating cylinder having an opening formed at a leading end and a plurality of petaloid parts surrounding the opening, and a pushing member that is movable in the accommodating member and pushes the tampon main body out of the accommodating cylinder through the opening, is provided, the method comprising:

performing a broadening process on the accommodating cylinder, the broadening process broadens the opening by outwardly bending each of the plurality of petaloid parts in the radial direction of the accommodating cylinder;

after performing the broadening process, inserting the pushing member into the accommodating cylinder through the opening; and

after performing the broadening process, inserting the tampon main body into the accommodating cylinder through the opening. With such a method of manufacturing a tampon, the pushing member and the tampon main body can be smoothly inserted into the accommodating cylinder.

In the above method of manufacturing a tampon, the method may include: mounting the accommodating cylinder on a mounting jig that is placed on a transport conveyor and transported by the transport conveyor in the transport direction, and

the broadening process is performed on the accommodating cylinder after mounting the accommodating cylinder on the mounting jig. With such a method of manufacturing a tampon, the broadening process is performed effectively.

In the above method of manufacturing a tampon, the broadening process may be a process of expanding the opening by inserting a tapered part of a jig provided at a leading-end part of the jig, the tapered part thickening from the leading-end side towards the rear end side, pressing the jig against each of the plurality of petaloid parts and bending the each of the plurality of petaloid parts outwardly in the radial direction. With such a method, the broadening process can be performed easily.

In the above method of manufacturing a tampon, in the performing of the broadening process, the jig is pressed against the each of the petaloid parts in such a manner that the each of the petaloid parts inclines outwardly in the radial direction at an angle of inclination between 1 degree and 45 degrees directly after the jig has been separated from each of the plurality of petaloid parts. With such a method, a disadvantage caused by an excessively large angle of inclination can be avoided.

In the above method of manufacturing a tampon, in mounting the accommodating cylinder onto the mounting jig, the accommodating cylinder is mounted on the mounting jig in such a manner that each of the plurality of petaloid parts is exposed from the leading end of the petaloid part to the rear end of the petaloid part. With such a method, since the jig can be properly pressed against each of the petaloid parts, the opening can be properly expanded.

In the above method of manufacturing a tampon, in the performing of the broadening process, the broadening process is performed a plurality of times on the accommodating cylinder. With such a method, the pushing member and the tampon main body can be inserted into the accommodating cylinder through the opening after securely broadening the opening.

In the above method of manufacturing a tampon, the performing of the broadening process includes:

performing the broadening process a plurality of times on the accommodating cylinder before inserting the pushing member into the accommodating cylinder; and

performing the broadening process again on the accommodating cylinder during a period of after having inserted the pushing member into the accommodating cylinder and until the tampon main body is inserted into the accommodating cylinder. With such a method, upon insertion of each of the pushing member and the tampon main body into the accommodating cylinder, the opening can be more securely broadened.

Further, an apparatus for manufacturing a tampon including a tampon main body, an accommodating cylinder accommodating the tampon main body, the accommodating cylinder having an opening formed at a leading end and a plurality of petaloid parts surrounding the opening, and a pushing member that is movable in the accommodating member and pushes the tampon main body out of the accommodating cylinder through the opening, can be achieved, the apparatus including:

a broadening process mechanism that performs a broadening process on the accommodating cylinder, the broadening process broadens the opening by outwardly bending each of the plurality of petaloid parts in the radial direction of the accommodating cylinder;

a pushing member-inserting mechanism that, after performing the broadening process, inserts the pushing member into the accommodating cylinder through the opening; and

a tampon main body-inserting mechanism that, after performing the broadening process, inserts the tampon main body into the accommodating cylinder through the opening. With such an apparatus for manufacturing a tampon, the pushing member and the tampon main body can be smoothly inserted into the accommodating cylinder.

In the above apparatus of manufacturing a tampon,

the broadening process mechanism may include a jig that performs the broadening process;

the jig may include a tapered part that thickens from the leading end towards the rear end that is provided at the leading-end part of a jig and a projecting part that is provided at the rear-end part and projects outside of the outer edge of the rear end of the tapered part; and

the broadening process mechanism may perform the broadening process that expands the opening by inserting the tapered part of the jig into the accommodating cylinder through the opening, pressing a surface that is located at the leading end of the projected part and that projects outside the outer edge against each of the plurality of petaloid parts and bending the each of the plurality of petaloid parts outwardly in the radial direction. With such a structure, the broadening process can be performed easily.

In the above apparatus of manufacturing a tampon,

the broadening process mechanism may include another jig that has a configuration different from that of the jig;

the other jig including another tapered part broadening from the leading end towards the rear end and provided at the leading-end part;

the leading end of the tapered part provided on the jig being flat;

the leading end of the other tapered part provided on the other jig is more pointed than the leading end of the tapered part provided on the jig; and

the broadening process mechanism performing, on the accommodating cylinder before performing the broadening process,

other broadening process that expands the opening by inserting the other tapered part of the jig into the accommodating cylinder through the opening, pressing an outer peripheral surface against each of the plurality of petaloid parts and bending the each of the plurality of petaloid parts outwardly in the radial direction. With an above apparatus for manufacturing a tampon, by performing the other broadening process, the subsequent broadening process can be properly performed.

—Structure of a Tampon—

Before describing a method of manufacturing and a manufacturing apparatus of a tampon of the present invention, the structure of a tampon2010manufactured by the method of manufacturing and the manufacturing apparatus will be described with reference toFIGS. 12 to 17.

FIGS. 12 and 13are cross-sectional views showing the components of the tampon2010.FIG. 12shows the tampon2010in a state where an inner cylinder2050is contracted andFIG. 13shows the tampon2010in a state where the inner cylinder2050is extended.FIG. 14is a diagram showing how a first inner cylinder2051and a second inner cylinder2052are joined and is an enlarged view of the area labeled “X” inFIG. 13.FIGS. 15A and 15Bare external views of an outer cylinder2040.FIG. 15Cis a diagram showing the outer cylinder2040shown inFIG. 15Afrom its leading-end side.FIG. 16is an external view of the first inner cylinder2051.FIG. 17is an external view of the second inner cylinder2052. In the following description, among the two end parts in the longitudinal direction of the tampon2010, the side that is inserted in to the vaginal cavity is referred to as a leading-end side and the opposite side is referred to as a rear-end side.

As shown inFIG. 12, the tampon2010of the present embodiment is a sanitary product including a tampon main body2020and an applicator2030. As shown in the same diagram, the tampon main body2020includes a cotton body2021and a cord2022. The cotton body2021is an absorbent body that blocks the vaginal cavity and absorbs menstrual blood etc, and is formed by cutting a cotton strip covered with non-woven fabric on both sides and by shaping into a substantially bullet like shape by heat forming. The cord2022extends through the rear-end side of the cotton body2021and is then held by a user when the cotton body2021inside the vaginal cavity is pulled out of the vaginal cavity. As shown inFIG. 12, the cord2022extends through the applicator2030and somewhat extends out of the rear end of the applicator.

The applicator2030is an aid device for guiding the tampon main body2020(specifically, the cotton body2021) into a vaginal cavity. As shown inFIG. 12, the applicator2030includes an outer cylinder2040which is an example of an accommodating cylinder that accommodates the tampon main body2020and an inner cylinder2050which is an example of a pushing member that pushes the tampon main body2020out of the outer cylinder2040.

The outer cylinder2040is a cylindrical body formed by injection molding a thermoplastic resin and has an appropriate flexibility. The outer cylinder2040includes a major diameter part2041provided on the leading-end part and a minor diameter part2042provided at the rear-end part and having an external diameter that is smaller than that of the major diameter part2041. The major diameter part2041is a part that has a slightly greater internal diameter than the diameter of the tampon main body2020and accommodates the tampon making body2020therein. The major diameter part2041is inserted into the vaginal cavity upon usage of the tampon2010with the tampon main body2020being accommodated therein. The tampon main body2020is accommodated in the major diameter part2041with its outer peripheral surface being in contact with the inner peripheral surface of the major diameter part2041. The minor diameter part2042is a part held by a user when using the tampon2010. It is to be noted that it is not necessary to provide the minor diameter part2042on the outer cylinder2040.

As shown inFIGS. 15A and 15B, the outer cylinder2040includes an opening formed at its leading end (hereinafter referred to as a leading-end opening2043) and a plurality of petaloid parts2044(in this embodiment, six petaloid parts) surrounding the leading edge opening2043. When shipping the tampon2010, each of the plurality of petaloid parts2044is inwardly bent in an arc in the radial direction of the outer cylinder2040as shown inFIG. 15A. Therefore, when the outer cylinder2040is inserted into the vaginal cavity, the leading-end part of the outer cylinder2040is substantially hemispherical as shown inFIGS. 12 and 13and the leading-end opening2043is substantially in a closed state as shown inFIG. 15C. On the other hand, as for the outer cylinder2040shortly after being injection molded, each of the plurality of petaloid parts2044is open (i.e., along the central axis of the outer cylinder2040, as shown inFIG. 15B), and the leading-end opening2043is in an open state.

Further, as shown inFIG. 15A, the outer cylinder2040includes an opening formed at its rear end (hereinafter, referred to as a rear-end opening2045) and an annular rib2046provided at a position slightly towards the leading-end side than the rear-end opening2045. Further, an annular stepped part2047is formed between the major diameter part2041and the minor diameter part2042.

The inner cylinder2050is a cylindrical body inserted into the minor diameter part2042of the outer cylinder2040. The inner cylinder2050is located at a position nearer to the rear end-side than the tampon main body2020in the outer cylinder2040and moves along the central axis of the outer cylinder2040to pushes the tampon main body2020from the rear towards the leading-end opening2043. Thereby, the tampon main body2020pushes each of the plurality of petaloid parts2044outwardly in the radial direction of the outer cylinder2040(in other words, opens the leading-end opening2043) and is pushed out of the outer cylinder2040. That is to say, the inner cylinder2050is movable in the outer cylinder2040and has a push-out function to push the tampon main body2020out of the outer cylinder2040through the leading-end opening2043.

It is to be noted that the inner cylinder2050of the present embodiment has an extendable structure to make the over all length of the tampon2010compact. In detail, when the inner cylinder2050is contracted as shown inFIG. 12, the length of the inner cylinder2050is shorter than the outer cylinder2040and becomes a length suitable for carrying the tampon2010. On the other hand, when the inner cylinder2050extends as shown inFIG. 13, the length of the inner cylinder2050will become a length sufficient to push the tampon main body2020out of the outer cylinder2040. As has been described above, in order to make the inner cylinder2050extendable, in this embodiment, the inner cylinder2050has a two-tier structure. In detail, as shown inFIG. 12, the inner cylinder2050of the present embodiment includes a first inner cylinder2051and a second inner cylinder2052that is slidably inserted into the first inner cylinder2051.

The first inner cylinder2051is a cylindrical body formed by injection molding plastics. The first inner cylinder2051has an external diameter that is slightly smaller than the internal diameter of the minor diameter part2042. As shown inFIG. 12, The first inner cylinder2051is slidably inserted in the minor diameter part2042. As shown inFIG. 16, an annular flange part2051ais formed on an outer peripheral surface of the leading-end part of the first inner cylinder2051. The flange part2051ahas an external diameter that is slightly smaller than the major diameter part2041of the outer cylinder2040and engages an inner surface of the stepped part2047, thereby preventing the inner cylinder2050from falling off from the rear-end opening2045of the outer cylinder2040. When the inner cylinder2050pushes the tampon main body2020out of the outer cylinder2040, the inner cylinder2050moves in such a manner that the outer peripheral surface of the flange part2051ais in contact with the inner peripheral surface of the major diameter part2041. Further, as shown inFIGS. 12 and 13, at the rear-end side on an inner peripheral surface of the first inner cylinder2051, an annular protrusion2051bextending inwardly in the radial direction of the first inner cylinder2051is provided.

The second inner cylinder2052is a cylindrical body formed by injection molding a thermoplastic resin. The second inner cylinder2052has an external diameter that is slightly smaller than the internal diameter of the first inner cylinder2051. The second inner cylinder2052is, when the inner cylinder2050is in a contracted state, inserted in the first inner cylinder2051as shown inFIG. 12and, when the inner cylinder2050is in an extended position, connected to the rear-end part of the first inner cylinder2051at the leading-end part of the second inner cylinder2052as shown inFIG. 13. Further, as shown inFIG. 17, on the outer peripheral surface of the leading-end part of the second inner cylinder2052, an arcuate flange part2052aand a protruded part2052blocated nearer to the rear-end side than the flange part2052ais formed. As shown inFIG. 14, the height of the protruded part2052bbecomes lower at the rear-end. It is to be noted that the gap between the flange part2052aand the protruded part2052bof the second inner cylinder2052is thicker than the thickness of the annular protrusion2051bof the first inner cylinder2051.

When the second inner cylinder2052is pulled towards the rear-end part, the annular protrusion2051bof the first inner cylinder2051will be located between the flange part2052aof the second inner cylinder2052and the protruded part2052b. In such a state, as shown inFIG. 14, the annular protrusion2051bengages the flange part2052aand the protruded part2052band thereby the first inner cylinder2051and the second inner cylinder2052are joined.

Further, as shown inFIGS. 12 and 13, a flared part2052cis formed at the rear end of the second inner cylinder2052. Preferably, the external diameter of the flared part2052cis greater than the internal diameter of the first inner cylinder2051and greater than the internal diameter of the minor diameter part2042of the outer cylinder2040.

—Method of Manufacturing a Tampon2010—

<<Outline of a Method of Manufacturing the Tampon2010>>

Next, a method of manufacturing the tampon2010of the present embodiment will be described with reference toFIG. 18andFIGS. 19A to 19D.FIG. 18is a flowchart showing how the tampon2010is manufactured.

FIGS. 19A to 19Dare diagrams in a series showing how the tampon2010is manufactured.

As shown inFIG. 18, the method of manufacturing the tampon2010includes a step of manufacturing each item constituting the tampon2010(S2001), a step of supplying the manufactured items to an assembly apparatus2100to be described later and to manufacture the tampon2010by assembling the tampon2010(S2002), a step of inspecting the manufactured tampon2010(S2003) and a step of wrapping the tampon2010(S2004).

In the main manufacturing step S2002, firstly, each of the items constituting the tampon2010is supplied to the assembling apparatus2100. As shown inFIG. 19A, at the time supplied to the assembling apparatus2100, the outer cylinder2040is in a state where the plurality of petaloid part2044are each in an open state (in other words, the leading-end opening2043is open). Then, as shown inFIG. 19A, the first inner cylinder2051is inserted into the outer cylinder2040through the leading-end opening2043of the outer cylinder2040. The first inner cylinder2051inserted in the outer cylinder2040will be in a state where its rear-end part protrudes through the rear-end opening2045of the outer cylinder2040and the flange part2051aengages with the inner wall of the stepped part2047of the outer cylinder2040(seeFIG. 19B).

Then, as shown inFIG. 19B, the second inner cylinder2052is inserted into the outer cylinder2040through the leading-end opening2043. The second inner cylinder2052inserted into the outer cylinder2040will be in a state where its rear-end part protrudes through the opening on the rear-end side of the first inner cylinder2051and the flange part2052aengages with the inner peripheral surface of the first inner cylinder2051(seeFIG. 19C). It is to be noted that, as shown inFIG. 19B, at the time the second inner cylinder2052is supplied to the assembling apparatus2100, a flared part2052cis not yet formed on the second inner cylinder2052. After the second inner cylinder2052has been inserted into the outer cylinder2040, the flared part2052cis formed by heat forming the rear-end part of the second inner cylinder2052. When the above-described steps are terminated, the assembly of the applicator2030is complete.

Then, as shown inFIG. 19C, the tampon main body2020is inserted into outer cylinder2040through the leading-end opening2043. Here, as shown inFIG. 19C, the tampon main body2020is inserted from its cord2022side. When the tampon main body2020is inserted in the outer cylinder2040, the cotton body2021is accommodated in the major diameter part2041of the outer cylinder2040and the cord2022extends out of the rear end of the applicator2030(specifically, out of the opening on the rear-end of the second inner cylinder2052.) When insertion of the tampon main body2020is terminated, the assembly of the tampon2010is complete.

After assembling the tampon2010, as shown inFIG. 19D, a process of heat forming is performed in which the leading-end part of the outer cylinder2040is formed into a substantially hemispherical shape by bending each of the plurality of petaloid parts2044in such a manner that it is inclined inwardly in the radial direction of the outer cylinder2040(hereinafter referred to as a leading-end processing). When the leading-end processing is terminated, the main manufacturing step S2002is complete.

It is to be noted that, as described below, the assembling apparatus2100includes a transport conveyor2110(seeFIG. 20). This transport conveyor2110intermittently carries out motions of transporting the assembled products in the transport direction (transport motions). Between the transport motions, i.e., when the assembled item is in a rest, each of the above-mentioned steps is sequentially performed.

<<Assembling Step of the Tampon2010>>

Next, regarding the above-mentioned main manufacturing step S2002, a step of assembling the tampon2010will be described in detail with reference toFIG. 20.FIG. 20is a diagram showing the assembling apparatus2100of the tampon2010.

The step of assembling the tampon2010is performed by the assembling apparatus2100shown inFIG. 20. This assembling apparatus2100is an example of an apparatus for manufacturing the tampon2010. As shown inFIG. 20, the assembling apparatus2100includes a transport conveyor2110, an outer cylinder supplying mechanism2120, an inner cylinder inserting mechanism2130as an example of the pushing-member inserting mechanism, a tampon main body inserting mechanism2140and a broadening mechanism2150. Hereinafter, each device constituting the assembling apparatus2100will be described.

The transport conveyor2110is a device that transports the outer cylinder2040and items inserted in the outer cylinder2040(first inner cylinder2051, second inner cylinder2052and tampon main body2020) in the transport direction (direction shown by an arrow inFIG. 20). A mount2160that mounts the outer cylinder2040thereon is placed on the transport conveyor2110and the mount2160is transported in the transport direction by the transport conveyor2110. Thereby, the outer cylinder2040mounted on the mount2160and the items inserted in the outer cylinder2040are transported in the transport direction together with the mount2160.

The mount2160is an example of a mounting jig and, as shown inFIG. 20, the outer cylinder2040is mounted thereon with the central axis of the outer cylinder2040lying along the vertical direction and the leading-end opening2043being facing substantially directly upwards. Circular holes (not shown) are formed in the mount2160in the vertical direction. The outer cylinder2040is mounted on the mount2160by being fitted into the circular hole from the minor diameter part2042side.

In this embodiment, as shown inFIG. 21, in a state where the outer cylinder2040is mounted on the mount2160, substantially half of the leading-end side of the outer cylinder2040is exposed. Therefore, in the state where the outer cylinder2040is mounted on the mount2160, each of the plurality of the petaloid parts2044is exposed from the leading end of the petaloid part2044to the rear end of the petaloid part2044.FIG. 21is a diagram showing the outer cylinder2040that is mounted on the mount2160.

The outer cylinder supplying mechanism2120is a mechanism that supplies the outer cylinder2040to the transport conveyor2110. As shown inFIG. 20, the outer cylinder supplying mechanism2120includes an outer cylinder transport feeder2121, a supplying path2122connected to the end of the transport path included in the outer cylinder transport feeder2121, and an outer cylinder setting part (not shown) that sets the outer cylinder2040that has passed through the supplying path2122to the mount2160.

The outer cylinder transport feeder2121is a parts feeder having a bowl-shaped vibratory table2121aand transports the outer cylinder2040by vibrating the vibratory table2121a. In detail, the vibratory table2121aforms a spiral transport path. By vibrating the vibratory table2121a, the outer cylinder transport feeder2121moves the outer cylinders2040accumulated at the base of the vibratory table2121asequentially from the base and along the transport path. The outer cylinder2040that has reached the end of the transport path is passed to the supplying path2122and travels on the supplying path2122.

As shown inFIG. 20, at the middle part and the end part of the supplying path2122, accumulating parts2122aand2122cthat temporarily accumulate the outer cylinders2040are provided. A drop chute2122bis formed between the accumulating parts2122aand2122c. The outer cylinders2040accumulated in the accumulating part2122aprovided at the middle part of the supplying path2122sequentially drop in the drop chute2122b. It is to be noted that in the drop chute2122b, a restriction mechanism (not shown) that restricts the orientation of the outer cylinder2040into a predetermined orientation is provided. While passing through the drop chute2122b, the outer cylinder2040is subjected to the action of the restriction mechanism and its orientation is restricted in such a manner that its leading-end comes out of the drop chute2122bfirst.

Then, the outer cylinders2040that came out of the drop chute2122bare accumulated in the accumulating part2122cprovided at the end part of the supplying path2122in such a manner that the outer cylinders2040are oriented in the same orientation. The accumulating part2122cprovided at the end of the supplying path2122is inclined with a downward slope. The outer cylinder2040that has slid down the accumulating part2122cand reached the end of the supplying path2122is captured at the above-mentioned outer cylinder setting part. Then, the outer cylinder setting part mounts the caught outer cylinder2040onto the mount2160placed on the transport conveyor2110.

The inner cylinder inserting mechanism2130is a mechanism that inserts the inner cylinder2050into the outer cylinder2040. In the present embodiment, after the broadening mechanism2150has performed the broadening process which is to be described later, the inner cylinder inserting mechanism2130inserts the inner cylinder2050through the leading-end opening2043of the outer cylinder2040into the outer cylinder2040that is mounted on the mount2160. Further, the inner cylinder inserting mechanism2130each includes a mechanism that inserts the first inner cylinder2051constituting the inner cylinder2050into the outer cylinder2040(hereinafter referred to as the first inner cylinder inserting mechanism2131) and a mechanism that inserts the second inner cylinder2052also constituting the inner cylinder2050into the outer cylinder2040(hereinafter referred to as the second inner cylinder inserting mechanism2132).

As shown inFIG. 20, the first inner cylinder inserting mechanism2131includes an inner cylinder transport feeder2133, an inner cylinder inserting part2135that inserts the first inner cylinder2051into the outer cylinder2040and a supplying tube2134provided between the inner cylinder transport feeder2133and the inner cylinder inserting part2135.

The inner cylinder transport feeder2133is a parts feeder having a structure substantially similar to the outer cylinder transport feeder2121and moves the first inner cylinders2051sequentially from the base of the bowl-shaped vibratory table2133aand along the spiral transport path formed by the vibratory table2133a. In the present embodiment, as shown inFIG. 20, the terminal end part of the transport path is constructed by a pair of rails2133b. The pair of rails2133bis a part of the vibratory table2133a.

Between the pair of rails2133b, a gap that is slightly longer than the external diameter of the first inner cylinder2051is formed. The first inner cylinder2051is held between the pair of rails2133band travels along the rails2133b. During this, the flange part2051aof the first inner cylinder2051hangs at the top part of the rails2133band the first inner cylinder2051is suspended from the rails2133b. That is to say, when the first inner cylinder2051travels along the rails2133b, the leading-end of the first inner cylinder2051is situated above the rear end. Then, after passing the leading end of the rails2133b, the first inner cylinder2051drops with its leading-end being located above the rear-end and is supplied to the inner cylinder inserting part2135through the supplying tube2134.

The inner cylinder inserting part2135receives the first inner cylinder2051that has dropped through the supplying tube2134and, when the outer cylinder2040is at a position below the inner cylinder inserting part2135, presses down the first inner cylinder2051it has received and inserts the first inner cylinder2051into the outer cylinder2040. In detail, as shown inFIG. 20, the inner cylinder inserting part2135includes a pressing member2135athat is movable in the vertical direction. By moving the pressing member2135adownwards when situated above the first inner cylinder2051, the first inner cylinder2051is pressed downwards. The inner cylinder inserting part2135inserts the first inner cylinder2051into the outer cylinder2040through the leading-end with the leading-end of the first inner cylinder2051being situated above the rear-end.

Detailed description of the structure of the second inner cylinder inserting mechanism2132will be omitted since the second inner cylinder inserting mechanism2132has a structure substantially similar to that of the first inner cylinder inserting mechanism2131. As shown inFIG. 20, the inner cylinder inserting part2135provided in the second inner cylinder inserting mechanism2132to insert the second inner cylinder2052into the outer cylinder2040is provided downstream in the transport direction of the transport conveyor2110of the inner cylinder inserting part2135provided in the first inner cylinder inserting mechanism.2131. That is to say, after the first inner cylinder inserting mechanism2131has inserted the first inner cylinder2051into the outer cylinder2040, the second inner cylinder inserting mechanism2132inserts the second inner cylinder2052into the outer cylinder2040.

The tampon main body inserting mechanism2140is a mechanism that inserts the tampon main body2020into the outer cylinder2040in which the first inner cylinder2051and the second inner cylinder2052have been inserted (in other words, the assembled applicator2030). It is to be noted that, after the broadening mechanism2150has performed the broadening process described below, the tampon main body inserting mechanism2140of the present embodiment inserts the tampon main body2020through the leading-end opening2043into the outer cylinder2040mounted on the mount2160.

As shown inFIG. 20, the tampon main body inserting mechanism2140includes a guide tube2141, a suction device2142and a pressing member2143. As shown inFIG. 20, the guide tube2141is a cylindrical body that covers the leading-end part of the outer cylinder2040. The guide tube2141is movable in the vertical direction with its central axis lying along the vertical direction. Further, the guide tube2141holds the tampon main body2020in its inner space. It is to be noted that the tampon main body2020is inserted into the guide tube2141by an inserting mechanism (not shown) and, as shown inFIG. 20, held within the guide tube2141with the cord2022being situated below the cotton body2021.

The suction device2142takes the air in from the rear-end side of the outer cylinder2040(specifically, from an opening at the rear-end side of the second inner cylinder2052inserted in the outer cylinder2040) when the guide tube2141covers the leading-end of the outer cylinder2040. The pressing member2143is situated directly above the upper-end opening of the guide tube2141and is held in a vertically movable manner. When the lower-end part of the guide tube2141covers the leading-end part of the outer cylinder2040, the pressing member2143is inserted into the guide tube2141through the upper-end opening of the guide tube2141. Thus, the pressing member2143presses down the tampon main body2020held in the guide tube2141and inserts the tampon main body2020into the outer cylinder2040through the leading-end opening2043of the outer cylinder2040.

When the outer cylinder2040is situated at a position where the leading-end opening2043opposes the lower-end opening of the guide tube2141, the tampon main body inserting mechanism2140of the above-mentioned structure moves the guide tube2141downwards. Thus the lower-end part of the guide tube2141covers the leading-end of the outer cylinder2040. The tampon main body inserting mechanism2140presses down the tampon main body2020held in the guide tube2141by the pressing member2143. As a result, the tampon main body2020is pushed out from the guide tube2141and is inserted into the outer cylinder2040through the leading-end opening2043of the outer cylinder2040.

It is to be noted that the tampon main body inserting mechanism2140operates the suction device2142when pushing the tampon main body2020out of the guide tube2141. Accordingly, when the tampon main body2020is inserted into the outer cylinder2040, the cord2022of the tampon main body2020is pulled downwards. As a result, the cord2022extends through the outer cylinder2040and is pulled out of the opening at the rear-end side of the second inner cylinder2052inserted in the outer cylinder2040(in other words, pulled out from the rear-end of the assembled applicator2030).

A broadening process is performed as a pre-process before inserting the inner cylinder2050and tampon main body2020into the outer cylinder2040and the broadening mechanism2150is a mechanism that performs the broadening process on the outer cylinder2040. The broadening process is a process that broadens the leading-end opening2043by bending each of the plurality of petaloid parts2044surrounding the leading-end opening2043of the outer cylinder2040outwardly in the radial direction. In this embodiment, as shown inFIG. 20, the broadening mechanism2150includes a first pusher unit2151, a second pusher unit2152and a third pusher unit2153.

The first pusher unit2151performs the broadening process on the outer cylinder2040before the first inner cylinder2051is inserted into the outer cylinder2040. The first inner cylinder2051is located on the upstream side than the first inner cylinder inserting mechanism2131in the transport direction of the transport conveyor2110. As shown inFIG. 22A, the first pusher unit2151includes a plurality of pushers2200and2210(in this embodiment, four pushers), an attachment plate2220on which the plurality of pushers2200and2210are mounted and a driving mechanism (not shown) that reciprocates the attachment plate2220in the vertical direction.FIG. 22Ais a diagram showing the first pusher unit2151.

The pushers2200and2210are an example of a jig for the first pusher unit2151to perform the broadening process on the outer cylinder2040and, in the present embodiment, made of metal. As shown inFIG. 22A, the plurality of pushers2200and2210are provided in a line in the transport direction.

When the outer cylinder2040comes into a position directly below one of the pushers2200and2210of the plurality of pushers2200and2210, the first pusher unit2151moves the plurality of pushers2200and2210downwardly together with the attachment plate2220by the driving mechanism. Thus, the leading-end parts of the pushers2200and2210are inserted into the outer cylinder2040through the leading-end opening2043of the outer cylinder2040and the pushers2200and2210are pushed against each of the inner surfaces of the plurality of petaloid parts2044. As a result, each of the plurality of petaloid parts2044is bent outwards in the radial direction of the outer cylinder2040by the pushers2200and2210and thus the leading-end opening2043is expanded.

As has been described above, the broadening process of the present embodiment is a process that inserts the leading-end parts of the pushers2200and2210into the outer cylinders2040through the leading-end opening2043, presses the pushers2200and2210against each of the plurality of petaloid parts2044and mechanically expands the leading-end openings2043by outwardly bending each of the petaloid parts2044by the pressure force that is applied to each of the petaloid parts2044.

The configuration of the pushers2200and2210will be described with reference toFIGS. 23 and 24.FIGS. 23 and 24are external views of each of the pushers2200and2210.

The plurality of pushers2200and2210has substantially the same shape. In detail, as shown inFIGS. 23 and 24, each of the plurality of pushers2200and2210is substantially funnel-shaped. Further in detail, each of the pushers2200and2210includes a tapered part2201,2211that is provided at the leading-end part and that gradually thickens from the leading-end part towards the read-end part and a projected part2202,2212that is provided at the rear-end and protrudes outside the outer edge of the rear-end of the tapered part2201,2211.

The tapered part2201,2211is a part that has substantially a shape of a frustum of a cone. As shown inFIGS. 23 and 24, the leading-end part of the tapered part2201,2211is a circular flat surface. The diameter of the leading-end of the tapered part2201,2211is shorter than the external diameter of the outer cylinder2040(specifically, the external diameter of the major diameter part2041). In the present embodiment, the diameter of the leading-end of the tapered part2201provided on the most upstream side pusher2200is approximately 5 mm and the diameter of the leading-end of the tapered part2211provided on the remaining pushers2100is approximately 7 mm. It is to be noted that the external diameter of the outer cylinder2040of the present embodiment is approximately 13.5 mm (seeFIG. 25A).

The diameter of the rear end of the tapered part2201,2211is greater than the external diameter of the outer cylinder2040(specifically, greater than the external diameter of the major diameter part2041). In the present embodiment, the diameter of the rear end of the tapered part2201provided on the most upstream side pusher2200is approximately 18 mm and the diameter of the rear end of the tapered part2211provided on the remaining pushers2100is approximately 20 mm.

As for the tapered part2201provided on the most upstream side pusher2200, a length from its leading-end to its rear end (in this embodiment, approximately 13 mm) is longer than a length from the leading-end to the rear end of the open petaloid part2044(in this embodiment, approximately 8.5 mm). It is to be noted that in this embodiment, a length from the leading-end to the rear end of the tapered part2211provided on the remaining pushers2210is approximately 8 mm.

Outer peripheral surfaces2201aand2211aof the tapered parts2201and2202are, as shown inFIGS. 23 and 24, curved surfaces that curves concavely and inwardly. In other words, a line of intersection between the outer peripheral surfaces2201aand2211aof the tapered parts2211and2211and a virtual plane lying through the central axis of the tapered parts2211and2211is an inwardly curved surface (seeFIG. 22A). In the present embodiment, a radius of curvature R of the outer peripheral surface2201aof the tapered part2201provided on the most upstream pusher2200is approximately 10 mm and the radius of curvature R of the outer peripheral surface2211aof the tapered part2211provided on the remaining pushers2210is approximately 6.5 mm.

The projected parts2202and2212are disk-like parts. The projected parts2202and2212include projected surfaces2202a,2212athat are located at the leading-end of the projected parts2202and2212and project outside than the outer edge of the rear end of the tapered parts2201and2211. The diameters of the projected parts2202and2212are greater than the external diameter of the outer cylinder2040. In the present embodiment, the diameter of the projected part2202provided on the most upstream pusher2200is approximately 30 mm and the diameter of the projected parts2212of the remaining pushers2210are approximately 36 mm. It is to be noted that other dimensions are as shown inFIGS. 23 and 24.

Further, in the present embodiment, a part of the outer surface of each pusher2200and2100pressed against the inner wall surface of the petaloid part2044is subject to a surface finishing process so as to prevent damages on the inner wall surface. In detail, the surface finishing process is performed in such a manner that the center line average roughness Ra of the part pressed against the inner surface of the petaloid part2044is within a predetermined numerical range (preferably, Ra=3.2 to 6.3 and a maximum of Ra=12.5 to 25).

Using the pushers2200and2210described above, the first pusher unit2151is capable of performing the above-mentioned broadening process in a simple manner. Now, referring toFIGS. 25A to 25D, the broadening process by the first pusher unit2151will be described.FIGS. 25A to 25Dare diagrams showing the broadening process. It is to be noted thatFIGS. 25A to 25Dillustrates a case in which the broadening process is performed using the most upstream pusher2200among the plurality of pushers2200and2210.

As shown inFIG. 25A, when the outer cylinder2040comes to a position directly below one of the pushers2200and2210of the plurality of pushers2200and2210, the first pusher unit2151moves the plurality of pushers2200and2210downwardly. At this time, the outer cylinder2040is in a state where its leading-end opening2043is facing substantially upwards. Thereby, the tapered parts2201and2211provided on the pushers2200and2210are inserted into the outer cylinder2040through the leading-end opening2043. Then, the outer peripheral surfaces2201aand2211aof the tapered parts2201and2211come into contact with each of the inner wall surfaces of the plurality of petaloid parts44. As a result, as shown inFIG. 25B, each of the petaloid parts2044bends in such a manner that it inclines outwardly in the radial direction of the outer cylinder2040along the outer surfaces2201aand2211aof the tapered parts2201and2211.

As has been described above, the outer peripheral surfaces2201aand2211aof the tapered parts2201and2211are curved surfaces. Therefore, when the outer peripheral surfaces2201aand2211aof the tapered parts2201and2211come into contact with the inner wall surface of each of the plurality of petaloid parts2044, each petaloid part will smoothly bend along the outer peripheral surfaces2201aand2211aof the tapered parts2201and2211.

When the tapered parts2201and2211are further inserted into the outer cylinder2040, as shown inFIG. 25C, the projected surfaces2202aand2212aof the projected parts2202and2212provided on the pushers2200and2210come into contact with the inner wall surface of each of the plurality of petaloid parts2044. Thus, each of the plurality of the petaloid parts2044will bend until it bends substantially at right angles outwardly in the radial direction. At this time, as shown inFIG. 25C, the first pusher unit2151pushes down the projected surfaces2202aand2212ain such a manner that the projected surfaces2202aand2212aare at a position of about 5 mm downwards from the leading-end position of the outer cylinder2040before the broadening process (leading-end position of the petaloid part2044).

Thereafter, as shown inFIG. 25D, the first pusher unit2151pulls out the pushers2200and2210from the outer cylinder2040by moving the pushers2200and2210upwardly. (In other words, separates the pushers2200and2210from each of the plurality of petaloid parts2044.)

According to the above-described procedure, when the first pusher unit2151performs the broadening process to the outer cylinder2040, the leading-end opening2043will be broadened as compared to the time before the broadening process. That is to say, in the present embodiment, the broadening process is performed that expands the leading-end opening2043by inserting the pushers2200and2210into the outer cylinder2040through the leading-end opening2043, pressing the projected surfaces2202aand2212aof the projected parts2202and2212of the pushers2200and2210to each of the plurality of the petaloid parts2044, and bending each of the petaloid outwardly in the radial direction of the outer cylinder2040.

After the above-mentioned broadening process, the outer cylinder2040is kept in a bent shape (specifically, the rear end of each of the petaloid parts2044is kept in a bent shape). In detail, as shown inFIG. 25D, after the broadening process, each of the plurality of petaloid parts2044are in an outwardly bent state in the radial direction of the outer cylinder2040. It is to be noted that the angle of inclination of the petaloid part2044(angle θ inFIG. 25D) may be greater than or equal to one degree.

It is to be noted that if the petaloid part2044inclines outwardly in the radial direction with an angle of 45 degrees or more, it will be disadvantageous for the leading-end process that processes the leading-end part of the outer cylinder2040into a substantially hemispherical form. Further, if the petaloid part2044is bent too much, it might damage the outer cylinder2040. Therefore, in the present embodiment, the above-mentioned bent shape is formed in such a manner that each of the plurality of the petaloid parts2044is inclined at an angle of inclination between one degree and 45 degrees outwardly in the radial direction. In other words, according to the broadening process of the present embodiment, directly after separating the pushers2200and2210from each of the plurality of petaloid parts2044, the pushers2200and2210are pressed against the each petaloid part2044in such a manner that the each petaloid part2044is inclined at an angle of inclination between one degree and 45 degrees outwardly in the radial direction.

In the present embodiment, the first pusher unit2151performs the broadening process on the outer cylinder2040that is mounted on the mount2160. As has been described above, the outer cylinder2040mounted on the mount2160is in a state where each of the plurality of the petaloid part2044is exposed from the leading-end of the petaloid part2044to the rear end of the petaloid part2044. Therefore, it facilitates the pressing of the pushers2200and2210against the inner wall surface of each of the petaloid parts2044and the bending of the each petaloid part2044outwardly in the radial direction. Further, since the pushers2200and2210are pressed against the inner wall surface of each of the plurality of the petaloid parts2044with the outer cylinder2040being mounted on the mount2160, a pressure force exerted on each petaloid part2044is substantially even between the petaloid parts2044.

The first pusher unit2151includes the plurality of pusher units2200and2210and performs the broadening process on the outer cylinder2040, every time the outer cylinder2040is positioned directly below each of the pushers2200and2210. That is to say, in this embodiment, the broadening process is performed a plurality of times (in this embodiment, four times) on the outer cylinder2040before inserting the first inner cylinder2051into the outer cylinder2040. Thus, with the leading-end opening2043being securely expanded, every item such as the first inner cylinder2051can be inserted into the outer cylinder2040through the leading-end opening2043.

Further, the first pusher unit2151of the present embodiment includes, in addition to the plurality of pushers2200and2210, other pushers (hereinafter, referred to as an auxiliary pusher2230) having a shape different from the plurality of the pushers2200and2210. Before performing the broadening process using each of the plurality of pushers2200and2210, the first pusher unit2151performs an auxiliary process on the outer cylinder2040using the auxiliary pusher2230. The auxiliary process is a process broadens the leading-end opening2043of the outer cylinder2040by inserting the auxiliary pusher2230into the outer cylinder2040through the leading-end opening2043of the outer cylinder2040, pressing the auxiliary pusher2230against the inner wall surface of each of the plurality of the petaloid parts2044and bending outwardly in the radial direction each of the plurality of petaloid parts2044. The auxiliary process corresponds to the other broadening process. Hereinafter, the auxiliary pusher2230will be described.

The auxiliary pusher2230is an example of the other jig and is made of a resin material such as plastics. Similarly to the plurality of pushers2200and2210, the auxiliary pusher2230is attached to the attachment plate2220. As shown inFIG. 22A, the auxiliary pusher2230is placed at a position upstream of the most upstream pusher2200in the transport direction. Further, as shown inFIG. 26, the auxiliary pusher2230includes other tapered part2231at the leading-end side of the auxiliary pusher2230that thickens from the leading-end towards the rear end.FIG. 26is an external view of the auxiliary pusher2230.

The other tapered part2231is a part that has substantially conical and has a leading-end that is more pointed than the leading-end of the tapered parts2201and2211provided on the pushers2200and2210. As shown inFIG. 26, in the present embodiment, the length between the leading-end to the rear end of the other tapered part2231is approximately 12 mm and the diameter of the rear end of the other tapered part2231is approximately 16 mm.

When the outer cylinder2040comes to a position directly below the auxiliary pusher2230, the first pusher unit2151having the auxiliary pusher2230of the above configuration moves the auxiliary pusher2230downwards. Thus, the other tapered part2231that is provided on the auxiliary pusher2230is inserted into the outer cylinder2040through the leading-end opening2043of the outer cylinder2040. When the other tapered part2231is inserted into the outer cylinder2040, an outer peripheral surface2231aof the other tapered part2231comes into contact with the inner wall surface of each of the plurality of petaloid parts2044. Thus, each of the plurality of the petaloid parts2044bends along the outer peripheral surface2231aof the other tapered part2231in the radial direction of the outer cylinder2040and thus the leading-end opening2043is expanded.

As has been described above, the auxiliary process is a process that inserts the other tapered part2231provided on the auxiliary pusher2230into the outer cylinders2040through the leading-end opening2043, presses the outer peripheral surface2231aof the other tapered part2231against each of the plurality of petaloid parts2044and expands the leading-end openings2043by outwardly bending each of the petaloid parts2044in the radial direction. The first pusher unit2151performs the above-mentioned auxiliary process on the outer cylinder2040before performing the broadening process. The reason for performing the auxiliary process before the broadening process will be described below.

As has been described above, the leading-ends of the tapered parts2201and2211provided on the pushers2200and2210of the present embodiment are flat surfaces. On the other hand, there are some cases where the outer cylinder2040has petaloid parts2044that are slightly inclining inwards at a step before performing the broadening process. If the tapered parts2201and2211of the pushers2200and2210are inserted into the outer cylinder2040whose petaloid parts2044are inclined inwards, the leading-ends of the tapered parts2201and2211might get caught at the petaloid parts2044. As a result, the petaloid parts2044will be rolled inward and it becomes difficult to insert the inner cylinder2050and the tampon main body2020into the outer cylinder2040. That is to say, when the broadening process of the present embodiment is performed on the outer cylinder2040whose petaloid parts2044are inclined inwards, it will be even more difficult to insert each item into the outer cylinder2040.

In contrast, the leading-end of the other tapered part2231of the auxiliary pusher2230is more pointed than the leading-end of the tapered parts2201and2211of the pushers2200and2210. Therefore, even if the auxiliary pusher2230is inserted into the outer cylinder2040whose petaloid parts2044are inclined inwards, the leading-end of the auxiliary pusher2230will not catch the petaloid parts2044inward and roll the petaloid part2044inwards.

When the other tapered part2231of the auxiliary pusher2230is inserted into the outer cylinder2040and the outer peripheral surface2231aof the other tapered part2231is pressed against the inner wall surface of the petaloid parts2044inclined inwards, the petaloid parts2044will open by bending outwards in the radial direction of the outer cylinder2040. That is to say, by performing the auxiliary process prior to the broadening process, it will be possible to keep the petaloid parts2044open in such a manner that the leading-ends of the tapered parts2201and2211of the pushers2200and2210do not catch the petaloid parts2044while performing the broadening process. As a result, the first pusher unit2151can properly perform the broadening process later on the outer cylinder2040.

The second pusher unit2152performs a broadening process on the outer cylinder2040from the time at which the first inner cylinder2051is inserted into the outer cylinder2040until the time at which the second inner cylinder2052is inserted into the outer cylinder2040. The second pusher unit2152is located between the first inner cylinder inserting mechanism2131and the second inner cylinder inserting mechanism2132in the transport direction. The third pusher unit2153performs a broadening process on the outer cylinder2040from the time at which the second inner cylinder2052is inserted into the outer cylinder2040until the time at which the tampon main body2020is inserted into the outer cylinder2040. The third pusher unit2153is located between the second inner cylinder inserting mechanism2132and the tampon main body inserting mechanism2140in the transport direction.

As shown inFIG. 22B, the second pusher unit2152and the third pusher unit2153are of substantially similar structure as the first pusher unit2151except that the number of pushers2210provided is different.FIG. 22Bis a diagram showing the second pusher unit2152. It is to be noted that the third pusher unit2153is not indicated in the drawings since it has the same structure as the second pusher unit2152.

As shown inFIG. 22B, each unit of the second pusher unit2152and the third pusher unit2153includes a pusher2210which is an example of the jig that performs the broadening process. This pusher2210is the same as the pusher2210that is located on the downstream side of the most upstream pusher2200, among the plurality of pushers2200and2210provided on the first pusher unit2151. That is to say, the broadening process can also be performed using a simple method on the second pusher unit2152and the third pusher unit2153.

The second pusher unit2152and the third pusher unit2153perform the broadening process with the substantially similar procedure as the broadening process performed by the first pusher unit2151. The second pusher unit2152performs the broadening process once on the outer cylinder2040from the time at which the first inner cylinder2051is inserted into the outer cylinder2040until the time at which the second inner cylinder2052is inserted into the outer cylinder2040. The third pusher unit2153performs the broadening process once on the outer cylinder2040from the time at which the second inner cylinder2052is inserted into the outer cylinder2040until the time at which the tampon main body2020is inserted into the outer cylinder2040.

It is to be noted that the second pusher unit2152and the third pusher unit2153do not perform the above-mentioned auxiliary process before performing the broadening process. (In other words, it does not include the auxiliary pusher2230.) This is because, at the step of performing the broadening process, each of the second pusher unit2152and the third pusher unit2153are at least inclined outwards in the radial direction and therefore it is not necessary to perform the auxiliary process again.

As has been described above, the broadening mechanism2150of the present embodiment performs the broadening process on the outer cylinder2040each time at a step before inserting each of the first pusher unit2151, the second pusher unit2152and the tampon main body2020into the outer cylinder2040. However, it is not limited to this and it is sufficient if the broadening process is performed at least from the time at which the outer cylinder2040is mounted on the mount2160until the time at which the inner cylinder2050(in this embodiment, the first inner cylinder2051) is inserted into the outer cylinder2040.

It is to be noted that in this embodiment, the broadening mechanism2150performs the broadening process on the outer cylinder2040in a state where the temperature of the pushers2200and2210is maintained at a temperature that is 50° C. below the melting point of the thermoplastic resin forming the outer cylinder2040. That is to say, the leading-end opening2043is not pushed and expanded by heating and softening the outer cylinder2040as in the case of heat forming but the leading-end opening2043is pushed and expanded only with the pressure force applied by the pushers2200and2210. Therefore, in the present embodiment, each of the petaloid parts2044will not be deformed by heat as in the case of heat forming. The temperature of the pusher2210may be within a range between the glass transition point of the thermoplastic resin and the temperature that is 50° C. below the melting point of the thermoplastic resin forming the outer cylinder2040and is preferably room temperature.

<Assembling Procedure of Tampon2010>

Next, the assembling procedure of the tampon2010by the assembling apparatus2100will be described with reference toFIG. 27.FIG. 27is a flowchart showing the assembling of the tampon2010.

As shown inFIG. 27, the assembling of the tampon2010starts with a step of mounting, by the outer cylinder supplying mechanism2120, the outer cylinder2040on the mount2160placed on the transport conveyor2110(S2011). The transport conveyor2110intermittently carries out motions of transporting the mount2160each time with a predetermined distance. On the other hand, the outer cylinder supplying mechanism2120is synchronized with the transport conveyor2110and mounts the outer cylinder2040on the mount2160between the transport motions (while the mount2160is at rest). In the present embodiment, as has been described above, the outer cylinder2040is mounted on the mount2160in such a manner that each of the plurality of the petaloid parts2044is exposed from the leading-end of the petaloid part2044to the rear end of the petaloid part2044.

Thereafter, by repeating the transport motions intermittently, the outer cylinder2040mounted on the mount2160is transported together with the mount2160to the downstream side in the transport direction. Then, at the time when the outer cylinder2040is located directly below the auxiliary pusher2230in the transport direction, the auxiliary process is performed on the outer cylinder2040mounted on the mount2160by the broadening mechanism2150(specifically, the first pusher unit2151) (S2012). The broadening mechanism2150is synchronized with the transport conveyor2110and performs the auxiliary process on the outer cylinder2040while the outer cylinder2040is at rest at a position directly below the auxiliary pusher2230.

After performing the auxiliary process, when the transport operation is performed once, the outer cylinder2040will be positioned directly under the most upstream side pusher2200, which is among the plurality of pushers2200and2210provided at the most upstream side. When the outer cylinder2040is at rest at such a position, the broadening mechanism2150(specifically, the first pusher unit2151) performs the broadening process on the outer cylinder2040(the outer cylinder2040mounted on the mount2160) (S2013).

In the present embodiment, as has been described above, in the broadening process, the projected surface2202aof the projected part2202of the most upstream-side pushers2200is pressed against the inner wall surface of each of the plurality of the petaloid parts2044. As a result, each of the plurality of the petaloid parts2044will be bent substantially at right angles outwardly in the radial direction of the outer cylinder2040. At the time when the most upstream-side pusher2200is pulled out of the outer cylinder2040(separate from each of the plurality of petaloid parts2044), the first broadening process terminates. Directly after the first broadening process, the outer cylinder2040is kept bent and each of the plurality of petaloid parts2044is in a state where it is inclined outwardly in the radial direction at an angle of inclination between 1 degree and 45 degrees.

After the first broadening process, when the transport operation is performed once, the outer cylinder2040comes to a position directly under the pusher2210that is adjacent to the most upstream-side pusher2200(in other words, the second pusher2210). At this position, when the outer cylinder2040is at rest, a second broadening process is performed on the outer cylinder2040. Thereafter, the transport operation and the broadening process are repeated in turns and four broadening processes are performed. As the number of implementation of the broadening process increases, the angle of inclination of the petaloid part2044directly after the broadening process will gradually increase. It is to be noted that, directly after the fourth broadening process, the angle of inclination of the petaloid part2044is between 1 degree and 45 degrees.

After having performed the broadening process on the outer cylinder2040for a plurality of times, the transport motion is repeated and the outer cylinder2040on which the broadening process is performed is transported towards the downstream side in the transport direction with the mount2160. Then, when the outer cylinder2040is located at a position below the first inner cylinder inserting mechanism2131, the first inner cylinder2051is inserted into the outer cylinder2040through the leading-end opening2043by the first inner cylinder inserting mechanism2131(S2014). That is to say, in the present embodiment, after transporting the outer cylinder2040subjected to the broadening process is transported together with the mount2160by the transport conveyor2110to the downstream side in the transport direction, the first inner cylinder2051is inserted into the outer cylinder2040. The first inner cylinder inserting mechanism2131synchronizes with the transport conveyor2110and the first inner cylinder inserting mechanism2131inserts the first inner cylinder2051into the outer cylinder2040while the outer cylinder2040is at rest below the first inner cylinder inserting mechanism2131.

After inserting the first inner cylinder2051into the outer cylinder2040, the transport motion is repeated. Then, while the outer cylinder2040is located directly below the pusher2210of the second pusher unit2152and the outer cylinder2040is at rest at that position, the broadening process is performed again on the outer cylinder2040(S2015). It is to be noted that, directly after the broadening process, the angle of inclination of the petaloid part2044is in a range from 1 degree to 45 degrees.

Thereafter, the transport motion is repeated and the second inner cylinder2052is inserted into the outer cylinder2040through the leading-end opening2043by the second inner cylinder inserting mechanism2132, while the outer cylinder2040is located at a position below the second inner cylinder inserting mechanism2132and is at rest at such a position (S2016). That is to say, the outer cylinder2040on which the broadening process was performed again after insertion of the first inner cylinder2051is transported together with the mount2160to the downstream side in the transport direction by the transport conveyor2110and then the second inner cylinder2052is inserted into the outer cylinder2040.

After inserting the second inner cylinder2052into the outer cylinder2040, the transport motion is repeated. Then, at the time when the outer cylinder2040(the first inner cylinder2051and the second inner cylinder2052) has reached in the transport direction at a position where a heat forming part (not shown) is provided, heat forming is performed that forms the flared part2052cat the rear-end part of the second inner cylinder2052(S2017). When the heat forming is terminated, the assembling of the applicator2030is complete.

After performing the heat forming, the transport motion is further repeated. Then, while the outer cylinder2040(in other words, the assembled applicator2030) is located at the position directly below the pusher2210of the third pusher unit2153and the outer cylinder2040is at rest at such a position, the broadening process is performed on the outer cylinder2040once more (S2018). It is to be noted that, directly after the broadening process, the angle of inclination of the petaloid part2044is in a range between 1 degree and 45 degrees.

Then, the transport operation is repeated and, when the outer cylinder2040(in other words, the assembled applicator2030) is located at a position below the tampon main body inserting mechanism2140, the tampon main body2020is inserted into the outer cylinder2040through the leading-end opening2043by the tampon main body inserting mechanism2140(S2019). That is to say, the outer cylinder2040subjected to the broadening process again after insertion of the inner cylinder2050(the first inner cylinder2051and the second inner cylinder2052) is transported together with the mount2160to the downstream side in the transport direction by the transport conveyor2110, and then the tampon main body2020is inserted into the outer cylinder2040. It is to be noted that the tampon main body inserting mechanism2140is also synchronized with the transport conveyor2110and, while the outer cylinder2040is at rest with the leading-end opening2043opposing the rear-end opening of the guide tube2141, inserts the tampon main body2020held in the guide tube2141into the outer cylinder2040through the leading-end opening2043.

According the above-described series of steps, the assembling of the tampon2010is completed. The assembled tampon2010is transported together with the mount2160, while being mounted on the mount, towards the step of processing the leading-end of the outer cylinder2040into a substantially hemispherical shape.

As has been described above, the manufacturing method of the tampon2010of the present embodiment includes mounting the outer cylinder2040on the mount2160(S2011), broadening the outer cylinder2040(S2013, S2015and S2018), inserting the inner cylinder2050into the outer cylinder2040through the leading-end opening2043after performing the broadening process (S2014and S2016), and inserting the tampon main body2020into the outer cylinder2040through the leading-end opening2043after performing the broadening process (S2019). Further, the broadening includes performing broadening process a plurality of times to the outer cylinder2040before inserting the first inner cylinder2051to the outer cylinder2040(S2013), performing a broadening process again to the outer cylinder2040during the time between insertion of the first inner cylinder2051into the outer cylinder2040and insertion of the inner cylinder2050into the outer cylinder2040(S2015) and performing a broadening process again on the outer cylinder2040during the time between insertion of the second inner cylinder2052into the outer cylinder2040and the insertion of the tampon main body2020into the outer cylinder2040(S2018).

—Effectiveness of Manufacturing Method of the Tampon2010of the Present Embodiment—

According to the manufacturing method of a tampon of the present embodiment, a broadening process is performed on the outer cylinder2040in which each of the plurality of the petaloid parts2044surrounding the leading-end opening2043of the outer cylinder2040is bent outwardly in the radial direction of the outer cylinder2040to broaden the leading-end opening2043. Then, after performing the broadening process, the inner cylinder2050(specifically, the first inner cylinder2051and the second inner cylinder2052) and the tampon main body2020are inserted into the outer cylinder2040through the leading-end opening2043. Thus, the inner cylinder2050and the tampon main body2020can be smoothly inserted into the outer cylinder2040. Hereinafter, the effectiveness of the manufacturing method of the tampon2010of the present embodiment will be described in detail.

When manufacturing the tampon2010of the present embodiment, since each of the outer cylinder2040, the inner cylinder2050and the tampon main body2020has the above-mentioned shape, the inner cylinder2050and the tampon main body2020will be inserted into the outer cylinder2040through the leading-end opening2043. That is to say, the leading-end opening2043serves as an insert inlet when inserting the inner cylinder2050and the tampon main body2020into the outer cylinder2040. As has been described above in the “Problem To Be Solved By The Invention,” in order to improve the production speed of the tampon2010, it is necessary to insert the inner cylinder2050and the tampon2010into the outer cylinder2040through the leading-end opening2043smoothly.

Now, there are cases where the petaloid parts2044incline inwardly in the radial direction during the period from injection molding of the outer cylinder2040to the mounting on the mount2160, due to a collision between outer cylinder2040, etc. When the petaloid parts2044incline inwardly in the radial direction, the leading-end opening2043becomes smaller and therefore it will be difficult to insert the inner cylinder2050and the tampon main body2020into the outer cylinder2040through the leading-end opening2043. Also, if the inner cylinder2050and the tampon main body2020are forced to be inserted into the outer cylinder2040under such a condition, the petaloid parts2044will be rolled into the outer cylinder2040and thus a defective tampon2010will be manufactured.

Particularly, like the tampon2010of the present embodiment, in cases where the difference between the external diameter of the inner cylinder2050and the internal diameter (specifically, the difference between the external diameter of the flange part2051aof the tampon main body2020and the internal diameter of the major diameter part2041) and the difference between the diameter of the tampon main body2020and the inner diameter of the outer cylinder2040are both very small, it becomes even more difficult to insert the inner cylinder2050and the tampon main body2020into the outer cylinder2040through the leading-end opening2043in a state where the leading-end opening2043has become small.

Therefore, in order to prepare for a case where the petaloid parts2044have inclined inwards, it is necessary to have some measures to facilitate the insertion of the inner cylinder2050and the tampon main body2020into the outer cylinder2040. Such measures may be, for example, making the external diameter of the inner cylinder2050and the diameter of the tampon main body smaller with respect to the inner diameter of the outer cylinder2040. With such a measure, insertion of the inner cylinder2050and the tampon main body2020into the tampon main body2020can be facilitated. However, the outer cylinder2040and the inner cylinder2050(or the outer cylinder2040and the tampon main body2020) will not fit well and may cause a problem when using the tampon2010.

On the other hand, in the present embodiment, the above-mentioned broadening process is performed on the outer cylinder2040before inserting the inner cylinder2050and tampon main body2020into the outer cylinder2040. Thus, the inner cylinder2050and the tampon main body2020can be inserted into the outer cylinder2040through the leading-end opening2043with the leading-end opening2043being broadened. As a result, the inner cylinder2050and the tampon main body2020can be smoothly inserted into the outer cylinder2040without changing the external diameter of the inner cylinder2050or the diameter of the tampon main body2020. Also, since each of the plurality of petaloid parts2044are bent outwardly in the radial direction of the outer cylinder2040, the above-mentioned problem, that is to say, the rolling-in of the petaloid part2044into the outer cylinder2040, can be prevented. Thereby, the tampon2010can be assembled properly.

As has been described above, by performing the broadening process on the outer cylinder2040before inserting the inner cylinder2050and the tampon main body2020into the outer cylinder2040, the inner cylinder2050and the tampon main body2020can be smoothly inserted into the outer cylinder2040and the tampon2010can be assembled properly. Therefore, according to the manufacturing method of the tampon2010of the present embodiment, the production speed of the tampon2010can be improved.

Further, in the present embodiment, the broadening process is performed on the outer cylinder2040after mounting the outer cylinder2040on the mount2160. That is to say, the broadening is a process in which broadening is performed on the outer cylinder2040after mounting the outer cylinder2040onto the mounting cylinder. This is because it is highly possible that the petaloid parts2044incline inwardly during the period from the injection molding of the outer cylinder2040to its mounting on the mount2160(specifically, during a period from the mounting onto the vibratory table2121of the outer cylinder transport feeder2121to the supplying to the transport conveyor2110). Therefore, if the broadening process is performed on the outer cylinder2040after mounting the outer cylinder2040on the mount2160, the broadening process will be performed effectively. The outer cylinder2040subjected to the broadening process is transported by the transport conveyor2110to the downstream side in the transport direction together with the mount2160and then the inner cylinder2050(the first inner cylinder2051and the second inner cylinder2052) is inserted into the outer cylinder2040. Thereafter, the outer cylinder2040in which the inner cylinder2050is inserted is transported by the transport conveyor2110to the downstream side in the transport direction together with the mount2160and then the tampon main body2020is inserted into the outer cylinder2040. Thus, it becomes easier to keep the leading-end opening2043in an open state until the inner cylinder2050and the tampon main body2020are inserted into the outer cylinder2040.

The present embodiment has been described with reference to an example in which the outer cylinder2040is kept mounted on the same mount2160during the period from the mounting of the outer cylinder2040onto the mount2160to the completion of the assembly of the tampon2010(seeFIG. 20), however, it is not limited to such an example. For example, with a structure in which a single outer cylinder2040is transported by a plurality of transport conveyors2110, when the single outer cylinder2040is passed from one transport conveyors2110to the other transport conveyor2110, the mount2160on which the outer cylinder2040is mounted is switched over. That is to say, there may be a case where the outer cylinder2040mounted on the mount2160should be mounted again on another mount2160. Even in such a case, by performing the broadening process on the outer cylinder2040after the outer cylinder2040is mounted on the mount2160on which the outer cylinder2040is mounted at first (in other words, the mount2160that receives the mount2160from the outer cylinder supplying mechanism2120), the broadening process can be performed efficiently.

Also, in the present embodiment, prior to inserting each of the second inner cylinder2052and the tampon main body2020into the outer cylinder2040, the broadening process is performed each time on the outer cylinder2040(S2013, S2015and S2018inFIG. 27). Thereby, when inserting each of the first inner cylinder2051, the second inner cylinder2052and the tampon main body2020into the outer cylinder2040, the leading-end opening2043can be broadened more securely.

The foregoing embodiments are merely for the purpose of elucidating the manufacturing method and manufacturing apparatus (assembling apparatus) of the tampon2010of the present invention and are not to be interpreted as limiting the invention. The invention can of course be altered and improved without departing from the gist thereof and equivalents are intended to be embraced therein. Also, the above-mentioned setting values, sizes and configurations, etc., are merely an example provided to show the effect of the present invention and is not to be interpreted as limiting the invention.

In the above-mentioned embodiment, the tampon2010having the inner cylinder2050of a two-tier structure as a pushing member has been described, but the present invention is not limited thereto. For example, it can be a tampon2010having the inner cylinder2050with a fixed length (which does not extend or contract).

Also, in the above-mentioned embodiment, the outer cylinder2040is mounted on the mount2160with the leading-end opening2043facing substantially directly upwards. That is to say, the above-mentioned embodiment has a structure that inserts the inner cylinder2050(the first inner cylinder2051and the second inner cylinder2052) and the tampon main body2020into the outer cylinder2040from above. However, it is not limited to such structure and can be a structure, for example, in which the outer cylinder2040is placed on the transport conveyor2110in a state where the leading-end opening2043is facing substantially directly laterally and the inner cylinder2050and the tampon main body2020can be inserted into the outer cylinder2040from the side. With such a structure, in order to perform the broadening process on the outer cylinder2040, the pushers2200and2210can be inserted into the outer cylinder2040from the side and pressed against each of the plurality of the petaloid part2044from the side.

Also, in the above-mentioned embodiment, although the inner cylinder2050and the tampon main body2020are separately inserted into the outer cylinder2040, it is not limited to such a structure. For example, it may be a structure in which the tampon main body2020is accommodated in the outer cylinder2040in a state it is inserted in the inner cylinder2050. When manufacturing the tampon2010of such a structure, after inserting the tampon main body2020into the inner cylinder2050, the inner cylinder2050in which the tampon main body2020is inserted may be inserted into the outer cylinder2040(That is to say, the tampon main body2020and the inner cylinder2050may be inserted into the outer cylinder2040at the same time).

Also, in the above-mentioned embodiment, a structure in which the broadening process is performed to the outer cylinder2040one by one. However, the present invention is not limited to such a structure and may be a structure in which the broadening process is performed on a plurality of outer cylinders2040at the same time. For example, as shown inFIG. 28, if a plurality of pushers2200and2210having mutually the same configuration are attached to the attachment plate2220in a group, the broadening process can be performed simultaneously on the plurality of outer cylinders2040(in the structure shown inFIG. 28, two outer cylinders2040).FIG. 28is a diagram showing the structure for simultaneously performing the broadening process on a plurality of outer cylinders2040and is a diagram corresponding toFIG. 22A.

An apparatus for manufacturing a tampon, the tampon including an absorbent body that absorbs liquid, an accommodating member that is cylindrical and accommodates the absorbent body, and a pushing member that moves inside the accommodating member and pushes the absorbent body out of the accommodating member, the accommodating member including a minor diameter part provided at a one-end part thereof and a major diameter part provided at an other-end part thereof, the major diameter part having an external diameter greater than that of the minor diameter part, is provided, the apparatus including:

an orienting mechanism that orients the accommodating member;

a first inserting mechanism that inserts the pushing member into the accommodating member oriented by the orienting mechanism; and

a second inserting mechanism that inserts the absorbent body into the accommodating member in which the pushing member is inserted,

the orienting mechanism including:

an opening through which the accommodating member is inputted;

a pair of first protruded parts located on one-end side in a longitudinal direction of the opening and protruding inwardly in an opposing manner into the opening; and

a pair of second protruded parts located on other-end side in the longitudinal direction of the opening and protruding inwardly in an opposing manner into the opening,

a gap between the pair of first protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part, and

a gap between the pair of second protruded parts being greater than the external diameter of the minor diameter part and smaller than the external diameter of the major diameter part.

With such an apparatus of manufacturing a tampon, since the accommodating cylinder received by the receiving part when there is the accommodating cylinder in the receiving part is discharged out of the second transport path, the accommodating cylinders can be prevented from being piled up before the receiving part. Thereby, the accommodating cylinders are prevented from being joined to each other and thus the accommodating cylinder can be supplied properly.

In the above apparatus for manufacturing a tampon,

the supplying mechanism may include:

a parts feeder having a placing table and moves the accommodating cylinder placed on the placing table towards the first transport path; and

a third transport path that transports the accommodating cylinder that is discharged out of the second transport path through the outlet to the placing table. With the above apparatus for manufacturing a tampon, the accommodating cylinder that is discharged out of the second transport can be transported again to the second transport path.

In the above apparatus for manufacturing a tampon,

each of the first transport path and the third transport path is inclined in such a manner that the accommodating cylinder slides down on each of the first transport path and the third transport path;

the receiving part is a recess between the first transport path and the third transport path;

the recess receives the accommodating cylinder which has slid down the first transport path when there is no accommodating cylinder in the recess and receives the accommodating cylinder which has slid down the first transport path when there is the accommodating cylinder in the recess in such a manner that it is piled on top of the accommodating cylinder in the recess; and

the side wall discharges the accommodating cylinder piled on top of the accommodating cylinder in the recess out of the second transport path through the outlet.

With such an apparatus for manufacturing a tampon, the accommodating cylinder can be discharged out of the second transport path by making use of the momentum acquired by the accommodating cylinder sliding down on the first transport path.

In the above apparatus for manufacturing a tampon,

the outlet may be a cutaway part formed in the side wall;

the side wall includes a retaining part provided below the cutaway part, the retaining part retains, in the receiving part, the accommodating cylinder received by the receiving part when there is no accommodating cylinder in the receiving part;

a height of the retaining part being smaller than the external diameter of the one-end part in the longitudinal direction of the accommodating cylinder;

a height of a part of the side wall that is adjacent to the retaining part in the second transport direction being greater than the external diameter of the one-end part in the longitudinal direction of the accommodating cylinder. With an apparatus for manufacturing a tampon of such a structure, the accommodating cylinder that cannot fit on the second transport path can be properly discharged out of the second transport path and the accommodating cylinder that is traveling on the second transport path can be prevented from falling off from the second transport path.

The above apparatus for manufacturing a tampon may further include:

an orienting mechanism that orients the accommodating cylinder;

the first transport path transporting the accommodating cylinder that has been oriented by the orienting mechanism into the first transport direction; and

the orienting mechanism orients the accommodating cylinder in such a manner that the accommodating cylinder travels on the first transport path with the one-end part in the longitudinal direction of the accommodating cylinder being located on an upstream side in the first transport direction than the other-end part in the longitudinal direction of the accommodating cylinder. When the accommodating cylinder is passed from the first transport path to the second transport path, the accommodating cylinder may collide with the side wall. If the one-end part in the longitudinal direction where the petaloid parts are provided collides with the side wall, the petaloid parts may bend inwardly. With the above structure, the petaloid parts can be prevented from bending inwards.

Further, a method of manufacturing a tampon including a tampon main body, an accommodating cylinder that accommodates the tampon main body, and a pushing member that moves in the accommodating cylinder and pushes the tampon main body out of the accommodating cylinder, a plurality of petaloid parts being provided at a one-end part in the longitudinal direction of the accommodating cylinder, may be provided, the method including:

supplying the accommodating cylinder by a supplying mechanism; and

inserting, by an inserting mechanism, the tampon main body and the pushing member into the accommodating cylinder supplied by the supplying mechanism,

the supplying mechanism including:

a first transport path transporting the accommodating cylinder in a first transport direction lying along the longitudinal direction of the accommodating cylinder; and

a second transport path transporting the accommodating cylinder in a second transport direction intersecting the longitudinal direction of the accommodating cylinder,

the second transport path including:

a receiving part that receives from the first transport path the accommodating cylinder that has traveled on the first transport path;

a side wall formed on an end part opposite to a side where the accommodating cylinder is passed to the receiving part from the first transport path in the first transport direction; and

an outlet that is formed in the side wall and discharges the accommodating cylinder out of the second transport path,

the side wall retains in the receiving part the accommodating cylinder which the receiving part has received when there is no accommodating cylinder in the receiving part and discharges out of the second transport path through the outlet the accommodating cylinder which the receiving part has received when there is an accommodating cylinder in the receiving part. As has been described above, with such a method of manufacturing a tampon, the other accommodating cylinder can be prevented from being caught into the one-end part in the longitudinal direction of the accommodating cylinder and thus the accommodating cylinder can be supplied properly.

In describing an apparatus and method of manufacturing a tampon of the present invention, the structure of the tampon3010manufactured by such apparatus and method of manufacturing will be described with reference toFIGS. 29 through 34.

FIGS. 29 and 30are cross-sectional views showing the components of the tampon3010.FIG. 29shows the tampon3010in a state where the inner cylinder3050is contracted andFIG. 30shows the tampon3010in a state where the inner cylinder3050is extended.FIG. 31is a diagram showing how the first inner cylinder3051and the second inner cylinder3052are joined and is an enlarged view of the area labeled “X” inFIG. 30.FIGS. 32A and 32Bare external views of the outer cylinder3040.FIG. 32Cis a diagram showing the outer cylinder3040shown inFIG. 32Afrom its leading-end side.FIG. 33is an external view of the first inner cylinder3051.FIG. 34is an external view of the second inner cylinder3052. In the following description, in the longitudinal direction of the tampon3010, the side which is inserted in to the vaginal cavity is referred to as a leading-end side and the opposite side is referred to as a rear-end side.

As shown inFIG. 29, the tampon3010of the present embodiment is a sanitary product including a tampon main body3020and an applicator3030. As shown in the same diagram, the tampon main body3020includes a cotton body3021and a cord3022. The cotton body3021is an absorbent body that blocks the vaginal cavity and absorbs liquid such as menstrual blood, and is formed by cutting a cotton strip covered with non-woven fabric on both sides and by shaping into a substantially bullet like shape by heat forming. The cord3022extends through the rear-end side of the cotton body3021and is then held by a user when the cotton body3021inside the vaginal cavity is pulled out of the vaginal cavity. As shown inFIG. 29, the cord3022extends through the applicator3030and somewhat extends out of the rear end of the applicator.

The applicator3030is an aid device for guiding the tampon main body3020(specifically, the cotton body3021) into a vaginal cavity. As shown inFIG. 29, the applicator3030includes an outer cylinder3040which is an example of a cylindrical accommodating member that accommodates the tampon main body3020and an inner cylinder3050which is an example of a pushing member that pushes the tampon main body3020out of the outer cylinder3040.

The outer cylinder3040is a cylindrical body formed by injection molding a thermoplastic resin and has an appropriate flexibility. The outer cylinder3040includes a major diameter part3041provided on the leading-end part (corresponds to a one-end part in the longitudinal direction) and a minor diameter part3042provided at the rear-end part (corresponds to an other-end part in the longitudinal direction) and having an external diameter that is smaller than that of the major diameter part3041. That is to say, an internal diameter of the leading-end part of the outer cylinder3040is greater than an external diameter of the rear-end part. It is to be noted that the dimensions of each part of the outer cylinder3040in the present embodiment is as shown inFIG. 32B.

The major diameter part3041is apart that has a slightly greater internal diameter than the diameter of the tampon main body3020and accommodates the tampon main body3020therein. The major diameter part3041is inserted into the vaginal cavity upon usage of the tampon3010with the tampon main body3020being accommodated therein. The tampon main body3020is accommodated in the major diameter part3041with its outer peripheral surface being in contact with the inner peripheral surface of the major diameter part3041. The minor diameter part3042is a part held by a user when using the tampon3010.

As shown inFIGS. 32A and 32B, the outer cylinder3040includes an opening formed at a leading end (hereinafter referred to as a leading-end opening3043) of the outer cylinder3040and a plurality of petaloid parts3044(in this embodiment, six petaloid parts) at the leading-end part of the outer cylinder3040and surrounding the leading edge opening3043. When shipping the tampon3010, each of the plurality of petaloid parts3044is inwardly bent in an arc in the radial direction of the outer cylinder3040as shown inFIG. 32A. Therefore, when the outer cylinder3040is inserted into the vaginal cavity, the leading-end part of the outer cylinder3040is substantially hemispherical as shown inFIGS. 29 and 30and the leading-end opening3043is substantially in a closed state as shown inFIG. 32C. On the other hand, as for the outer cylinder3040shortly after being injection molded, each of the plurality of petaloid parts3044is open (i.e., along the central axis of the outer cylinder3040, as shown inFIG. 32B), and the leading-end opening3043is in an open state.

Further, as shown inFIG. 32A, the outer cylinder3040includes an opening formed at a rear end of the outer cylinder3040(hereinafter, referred to as a rear-end opening3045) and an annular rib3046provided at a position slightly towards the leading-end side than the rear-end opening3045. Further, an annular stepped part3047is formed between the major diameter part3041and the minor diameter part3042.

The inner cylinder3050is a cylindrical body inserted into the minor diameter part3042of the outer cylinder3040. The inner cylinder3050is located at a position nearer to the rear end-side than the tampon main body3020in the outer cylinder3040and moves along the central axis of the outer cylinder3040to pushes the tampon main body3020from the rear towards the leading-end opening3043. Thereby, the tampon main body3020pushes each of the plurality of petaloid parts3044outwardly in the radial direction of the outer cylinder3040(in other words, opens the leading-end opening3043) and is pushed out of the outer cylinder3040. That is to say, the inner cylinder3050is movable in the outer cylinder3040and has a push-out function to push the tampon main body3020out of the outer cylinder3040through the leading-end opening3043.

It is to be noted that the inner cylinder3050of the present embodiment has an extendable structure to make the over all length of the tampon3010compact. In detail, when the inner cylinder3050is contracted as shown inFIG. 29, the length of the inner cylinder3050is shorter than the outer cylinder3040and becomes a length suitable for carrying the tampon3010. On the other hand, when the inner cylinder3050extends as shown inFIG. 30, the length of the inner cylinder3050will be a length sufficient to push the tampon main body3020out of the outer cylinder3040. As has been described above, in order to make the inner cylinder3050extendable, in this embodiment, the inner cylinder3050has a two-tier structure. In detail, as shown inFIG. 29, the inner cylinder3050of the present embodiment includes a first inner cylinder3051and a second inner cylinder3052that is slidably inserted into the first inner cylinder3051.

The first inner cylinder3051is a cylindrical body formed by injection molding plastics. The first inner cylinder3051has an external diameter that is slightly smaller than the internal diameter of the minor diameter part3042. As shown inFIG. 29, The first inner cylinder3051is slidably inserted in the minor diameter part3042. As shown inFIG. 33, an annular flange part3051ais formed on an outer peripheral surface of the leading-end part of the first inner cylinder3051. The flange part3051ahas an external diameter that is slightly smaller than the major diameter part3041of the outer cylinder3040and engages with an inner surface of the stepped part2047, thereby preventing the inner cylinder3050from falling off from the rear-end opening2045of the outer cylinder3040. When the inner cylinder3050pushes the tampon main body3020out of the outer cylinder3040, the inner cylinder3050moves in such a manner that the outer peripheral surface of the flange part3051ais in contact with the inner peripheral surface of the major diameter part3041. Further, as shown inFIGS. 29 and 30, at the rear-end side on an inner peripheral surface of the first inner cylinder3051, an annular protrusion3051bextending inwardly in the radial direction of the first inner cylinder3051is provided.

The second inner cylinder3052is a cylindrical body formed by injection molding a thermoplastic resin. The second inner cylinder3052has an external diameter that is slightly smaller than the internal diameter of the first inner cylinder3051. The second inner cylinder3052is, when the inner cylinder3050is in a contracted state, inserted in the first inner cylinder3051as shown inFIG. 29and, when the inner cylinder3050is in an extended position, connected to the rear-end part of the first inner cylinder3051at the leading-end part of the second inner cylinder3052as shown inFIG. 30. Further, as shown inFIG. 34, on the outer peripheral surface of the leading-end part of the second inner cylinder3052, an arcuate flange part3052aand a protruded part3052blocated nearer to the rear-end side than the flange part3052ais formed. As shown inFIG. 31, the height of the protruded part3052bbecomes lower at the rear-end. It is to be noted that the gap the gap between the flange part3052aof the second inner cylinder3052and the protruded part3052bis thicker than the thickness of the annular protrusion3051bof the first inner cylinder3051.

When the second inner cylinder3052is pulled towards the rear-end part, the annular protrusion3051bof the first inner cylinder3051will be located between the flange part3052aof the second inner cylinder3052and the protruded part3052b. In such a state, as shown inFIG. 31, the annular protrusion3051bengages the flange part3052aand the protruded part3052band thereby the first inner cylinder3051and the second inner cylinder3052are joined.

Further, as shown inFIGS. 29 and 30, a flared part3052cis formed at the rear end of the second inner cylinder3052. Preferably, the external diameter of the flared part3052cis greater than the internal diameter of the first inner cylinder3051and greater than the internal diameter of the minor diameter part3042of the outer cylinder3040.

—Method of Manufacturing a Tampon3010—

A method of manufacturing the tampon3010of the present embodiment will be described with reference toFIGS. 35A to 35D.FIGS. 35A and 35Bare flowcharts showing how a tampon3010is manufactured.FIGS. 36Ato36D are diagrams in a series showing how a tampon3010is manufactured.

As shown inFIG. 35A, the method of manufacturing the tampon3010includes a step of manufacturing each item constituting the tampon3010(S3001), a step of supplying the manufactured items to an assembly apparatus3100to be described later and to manufacture the tampon3010by assembling the tampon3010(hereinafter referred to as a main manufacturing step S3002), a step of inspecting the manufactured tampon3010(S3003) and a step of wrapping the tampon3010(S3004).

As shown inFIG. 35B, the main manufacturing step S3002starts with a step of supplying the injection molded outer cylinder3040(S3011). This step is performed by the supplying mechanism3120described later. It is to be noted that the outer cylinder3040at the step of being supplied by the supplying mechanism is in a state where the plurality of petaloid part3044are each in an open state (in other words, the leading-end opening3043is open). Thereafter, a step of inserting the tampon main body3020and the inner cylinder3050into the outer cylinder3040supplied by the supplying mechanism3120is performed (S3012). This step is performed by the inserting mechanism3130to be described later. The tampon3010is gradually assembled in accordance with the progress of the step.

Now, the procedure of inserting the tampon main body3020and the inner cylinder3050into the outer cylinder3040is described in detail. As shown inFIG. 36A, the first inner cylinder2051is inserted into the outer cylinder3040through the leading-end opening3043of the outer cylinder3040. The first inner cylinder3051inserted into the outer cylinder3040will be in a state where its rear-end part protrudes from the rear-end opening3045of the outer cylinder3040and the flange part3051aengages the inner wall of the stepped part3047of the outer cylinder3040(seeFIG. 36B).

Then, as shown inFIG. 36B, the second inner cylinder3052is inserted into the outer cylinder3040through the leading-end opening3043. The second inner cylinder3052inserted in the outer cylinder3040will be in a state where its rear-end part protrudes through the opening on the rear-end side of the first inner cylinder3051and the flange part3052aengages with the inner peripherals surface of the first inner cylinder3051(seeFIG. 36C). It is to be noted that, as shown in FIG.36B, at the time supplied to the assembling apparatus3100, a flared part3052cis not yet formed on the second inner cylinder3052. After the second inner cylinder3052is inserted into the outer cylinder3040, the flared part3052cwill be formed by thermoforming the rear-end part of the second inner cylinder3052. When the above-described steps are terminated, the assembly of the applicator3030is complete.

Then, as shown inFIG. 36C, the tampon main body3020is inserted into outer cylinder3040through the leading-end opening3043. At this point, as shown inFIG. 36C, the tampon main body3020is inserted from its cord3022side. When the tampon main body3020is inserted in the outer cylinder3040, the cotton body3021is accommodated in the major diameter part3041of the outer cylinder3040and the cord3022extends out of the rear end of the applicator3030(specifically, out of the opening on the rear-end of the second inner cylinder3052). When the insertion of the tampon main body3020is terminated, the assembly of the tampon3010is complete.

After assembling the tampon3010in a manner described above, as shown inFIG. 36D, a process of heat forming is performed in which the leading-end of the outer cylinder3040is formed into a substantially hemispherical shape by bending each of the plurality of petaloid parts2044in such a manner that it is inclined inwardly in the radial direction of the outer cylinder3040(hereinafter referred to as a leading-end processing). When the leading-end processing is terminated, the main manufacturing step S3002is complete.

It is to be noted that as described below, the assembling apparatus3100includes an assembling conveyor3110(seeFIG. 37). This assembling conveyor3110intermittently carries out motions of transporting the assembled product in the transport direction (transport motions). Between the transport motions, i.e., when the assembled item is in a rest, each of the above-mentioned steps is sequentially performed.

In the above-mentioned main manufacturing step S3002, a series of steps of assembling the tampon3010is performed by the assembling apparatus3100shown inFIG. 37.FIG. 37is a diagram showing the assembling apparatus3100. This assembling apparatus3100is an example of a manufacturing apparatus of the tampon3010and as shown inFIG. 37, includes an assembling conveyor3110, a supplying mechanism3120and an inserting mechanism3130.

The assembling conveyor3110is a device that transports the outer cylinder3040and items inserted in the outer cylinder3040(first inner cylinder3051, second inner cylinder3052and tampon main body3020) in the transport direction (direction indicated by an arrow inFIG. 37). A mount3160that mounts the outer cylinder3040thereon is placed on the assembling conveyor3110and the mount3160is transported in the transport direction by the assembling conveyor3110. Thereby, the outer cylinder3040mounted on the mount3160and the items inserted in the outer cylinder3040are transported in the transport direction together with the mount3160. Circular holes3161(for example, seeFIG. 39) are formed in the mount3160in the vertical direction and the outer cylinder3040is mounted on the mount3160by fitting into the circular hole3161from the rear-end side. The outer cylinder3040mounted on the mount3160will be in a state that the central axis of the outer cylinder3040lies along the vertical direction and the leading-end opening3043faces directly upwards as shown inFIG. 37.

The supplying mechanism3120is a mechanism that individually supplies the injection molded outer cylinder3040. As shown inFIG. 37, some of the outer cylinders3040supplied by the supplying mechanism3120are mounted on the mount3160and are transported by the assembling conveyor3110together with the mount3160. It is to be noted that an orienting mechanism3170that orients the outer cylinders3040is built in the supplying mechanism3120of the present embodiment. (In other words, the assembling apparatus3100of the present embodiment includes an orienting mechanism3170.) This orienting mechanism3170orients the outer cylinders3040in such a manner that the orientation of the outer cylinder3040supplied by the supplying mechanism3120is in the predetermined orientation. Since the outer cylinders3040are oriented by the orienting mechanism3170, the outer cylinders3040are mounted on the mount3160in a state shown inFIG. 37. (That is to say, the central axis of the outer cylinder3040lies along the vertical direction and the leading-end opening3043faces directly upwards.) Details of each of the supplying mechanism3120and the orienting mechanism3170will be described later.

The inserting mechanism3130is a mechanism that inserts the inner cylinder3050and the tampon main body3020into the outer cylinder3040mounted on the mount3160that is apart of the outer cylinders3040supplied by the supplying mechanism3120. As shown inFIG. 37, the inserting mechanism3130includes an inner cylinder inserting mechanism3140that inserts the inner cylinder3050into the outer cylinder3040and a tampon main body inserting mechanism3150that inserts the tampon main body3020into the outer cylinder3040.

The inner cylinder inserting mechanism3150inserts the inner cylinder3050into the outer cylinder3040mounted on the mount3160through the leading-end opening3043of the outer cylinder3040. It is to be noted that the inner cylinder inserting mechanism3140of the present embodiment includes a mechanism that inserts a first inner cylinder3051constituting the outer cylinder3040into the outer cylinder3040(hereinafter referred to as a first inner cylinder inserting mechanism3141) and a mechanism that similarly inserts the second inner cylinder3052constituting the inner cylinder3050into the outer cylinder3040(hereinafter referred to as a second inner cylinder inserting mechanism3142) respectively.

As shown inFIG. 37, the first inner cylinder inserting mechanism3141includes an inner cylinder feeder3143, an inner cylinder pressing device3145that presses and inserts the first inner cylinder3051into the outer cylinder3040and a tube3144provided between the inner cylinder feeder3143and the inner cylinder pressing device3145.

The inner cylinder feeder3143is a parts feeder including a bowl-shaped vibratory table3143a. By vibrating the vibratory table3143a, the inner cylinder feeder3143moves the first inner cylinders3051accumulated at the bottom part of the vibratory table3143asequentially and spirally from the bottom part.

Also, as shown inFIG. 37, a pair of rails3143bis connected to the terminal end part of the vibratory table3143a. Between the pair of rails3143b, a gap that is slightly longer than the external diameter of the first inner cylinder3051is formed. The first inner cylinder3051that has moved on the vibratory table3143atravels along the rails3143bwhile being held between the pair of rails3143b. At this time, the flange part3051aof the first inner cylinder3051hangs at the top part of the rails3143band the first inner cylinder3051will be suspended from the rails3143b. Then, after passing the terminal end of the rails3143b, the first inner cylinder3051drops with the leading-end of the first inner cylinder3051being located above the rear-end and supplied to the inner cylinder pressing device3145through the tube3144.

The inner cylinder pressing device3145receives the first inner cylinder3051that has dropped through the tube3144. When the outer cylinder3040is transported to a position below the inner cylinder pressing part3145by the assembly conveyor3110, the inner cylinder pressing device3145presses down the received first inner cylinder3050by a pressing jig3145a. Thus, the first inner cylinder3051is inserted into the outer cylinder3040through the leading-end opening3043of the outer cylinder3040.

Since the second inner cylinder inserting mechanism3142has a structure that is substantially similar to that of the first inner cylinder inserting mechanism3141, it will not be described in detail here. As shown inFIG. 37, the second inner cylinder inserting mechanism3142is provided at a downstream position, in the transport direction of the transport conveyor2110, than the first inner cylinder inserting mechanism3141. Accordingly, the second inner cylinder inserting mechanism3142inserts the second inner cylinder3052into the outer cylinder3040in which the first inner cylinder3051is inserted.

The tampon main body inserting mechanism3140inserts the tampon main body3020into the outer cylinder3040through the leading-end opening3043of the outer cylinder3040. The tampon main body inserting mechanism3150is provided on the downstream side of the inner cylinder inserting mechanism3140in the transport direction of the assembling conveyor3110. Accordingly, the tampon main body inserting mechanism3150inserts the tampon main body3020into the outer cylinder3040in which the first inner cylinder3051and the second inner cylinder3052are inserted (in other words, the assembled applicator3030). As shown inFIG. 37, the tampon main body inserting mechanism3150includes a guide tube3151, a suction device3152and a tampon main body pressing device3153.

The guide tube3151is a cylindrical body that guides the tampon main body3020when the tampon main body3020is inserted into the outer cylinder3040. With the tampon main body3020being held inside the guide tube3151, the guide tube3151is connected to the outer cylinder3040mounted on the mount3160as shown inFIG. 37. In detail, when the outer cylinder3040is transported to the position below the guide tube3151by the assembling conveyor3110, the guide tube3151is lowered. Thus, the leading-end part of the outer cylinder3040will fit into the lower end of the guide tube3151. It is to be noted that the tampon main body3020is held inside the guide tube3151in such a manner that the cord3022hangs down at a position below the cotton body3021.

The tampon main body pressing device3153presses down the tampon main body3020held inside the guide tube3151in a state that the guide tube3151is connected to the outer cylinder3040. Thereby, the tampon main body3020moves inside the guide tube3151and is inserted into the outer cylinder3040connected to the guide tube3151from the side where the cord3022is provided.

The suction device3152takes the air in from the rear-end side of the outer cylinder3040(specifically, an opening at the rear-end side of the second inner cylinder3052inserted in the outer cylinder3040) while the tampon main body pressing device3153is pressing the tampon main body3020. According to the suction of the suction device3152, the cord3022will be pulled directly downwards when the tampon main body3020is inserted into the outer cylinder3040. As a result, the cord3022will smoothly passes through the leading-end opening3043of the outer cylinder3040. It is to be noted that at the time when the tampon main body3020is accommodated into the outer cylinder3040, the cord3022is somewhat pulled out of the rear-end opening (in other words, the rear end of the assembled applicator3030) of the second inner cylinder3052inserted into the outer cylinder3040.

The structure of the above-described supplying mechanism3120will be described with reference toFIGS. 38 and 39.FIG. 38is an enlarged view of the supplying mechanism3120shown inFIG. 37.FIG. 39is a top plan view of the supplying mechanism3120.

As has been described above, the supplying mechanism3120supplies the injection molded outer cylinders3040individually. That is to say, the outer cylinder3040supplied by the supplying mechanism3120is set at regular intervals on the assembling conveyor3110. (Specifically, it is mounted on the mount3160placed on the assembling conveyor3110.) Also, as shown inFIG. 38, the supplying mechanism3120includes an outer cylinder feeder3121, a transport path3122and an outer cylinder setting part3123. Hereinafter, each component of the supplying mechanism3120will be described.

The outer cylinder feeder3121is a parts feeder3121including a bowl-shaped vibratory table3121aand is a device that moves the outer cylinder3040mounted on the vibratory table3121aby vibrating the vibratory table3121a. Here, the vibratory table3121ais an example of the placing table. Then the injection molded outer cylinders3040are once accumulated at the bottom part of the vibratory table3121aand then move spirally from the bottom part as shown inFIG. 39. It is to be noted that the outer cylinder3040moves on the vibratory table3121ain such a manner that its direction of movement (inFIG. 39, the direction shown by a broken-line arrow) lies along the longitudinal direction of the outer cylinder3040. Then, the outer cylinder feeder3121moves the plurality of outer cylinders3040in such a manner that the plurality of outer cylinders3040aligns in the direction of movement on the vibratory table3121a.

The transport path3122receives the outer cylinder3040that has moved on the vibratory table3121aand to transport the outer cylinder3040. As shown inFIG. 38, the transport path3122includes, from the top, a guide path3200, a drop chute3210, a first transport path3220, a second transport path3230and a third transport path3240.

The guide path3200is apart of the transport path3122that receives the outer cylinder3040from the outer cylinder feeder3121and guides the outer cylinder3040to the drop chute3210. The guide path3200is formed at the upstream side end part of the transport path3122and is located at the upper most position in the transport path3122. The starting end part of the guide path3200is directly connected to the vibratory table3121aand the terminal end part of the guide path3200extends to an opening3211in the drop chute3210. After being passed to the guide path3200, the outer cylinder3040that has moved on the vibratory table3121ais guided by the guide path3200and moves towards the drop chute3210. It is to be noted that since the starting end part of the guide part3200is directly connected to the vibratory table3121a, the vibration of the vibratory table3121ais transferred to the guide part3200. Therefore, since the guide part3200vibrates by the vibration transferred from the vibratory table3121a, the outer cylinder3040will move on the guide part3200.

Also, as shown inFIGS. 38 and 39, when the outer cylinder3040is passed from the vibratory table3121ato the guide part3200, the orientation of the outer cylinder3040is changed. In detail, the orientation of the outer cylinder3040that has moved on the vibratory table3121ain the longitudinal direction of the outer cylinder3040is changed in such a manner that it moves in a direction intersecting the longitudinal direction of the outer cylinder3040on the guide path3200. The purpose of changing the orientation of the outer cylinder3040is to input the outer cylinder3040into the drop chute3210in such a state that the longitudinal direction of the outer cylinder3040lies along the longitudinal direction of the opening3211of the drop chute3210. The outer cylinder3040the orientation of which has turned over in a manner described above travels on the guide path3200while maintaining such an orientation. On the other hand, the outer cylinder3040whose orientation was not properly changed will be rejected and returns to the bottom part of the vibratory table3121a.

The outer cylinder3040that has moved on the guide path3200is inputted into the drop chute3210one by one. Here, a number of outer cylinders3040passed from the outer cylinder feeder3121to the guide path3200at a unit time is greater than a number of outer cylinders3040inputted into the drop chute3210from the guide path3200at a unit time. Therefore, on the guide path3200, as shown inFIGS. 38 and 39, the outer cylinders3040are temporarily accumulated side-by-side (specifically, in a state that they are aligned in a direction intersecting the longitudinal direction of the outer cylinder3040).

The drop chute3210is a part of the transport path3122through which the outer cylinder3040that has traveled on the guide path3200is dropped substantially directly downwards. The opening3211in the drop chute3210is substantially rectangular and is adjacent to the terminal end part of the guide path3200. Among the outer cylinders3040accumulated on the guide path3200, the outer cylinder3040located at the most terminal part of the guide path3200is inputted and dropped into the drop chute3210through the opening3211. As has been described above, the outer cylinder3040is inputted into the drop chute3210with the longitudinal direction of the outer cylinder3040lying along the longitudinal direction of the opening3211.

Further, the orienting mechanism3170is provided at the opening3211of the drop chute3210. While being inputted into the drop chute3210from the opening3211, the outer cylinder3040is oriented by the orienting mechanism3170. To be more specifically, the orientation of the outer cylinder3040is oriented in such a manner that the rear end part of the outer cylinder3040drops before the leading-end part. Thereafter, the outer cylinder3040maintains the orientation mentioned above and drops to the lower-end part of the drop chute3210.

The first transport path3220is a part that is connected to the lower-end part of the drop chute3210and transports the outer cylinder3040that has dropped through the drop chute3210. The outer cylinder3040that has been sent from the outer cylinder feeder3121reaches the first transport path3220via the guide path3200and the drop chute3210and then transported by the first transport path3220. In other words, the outer cylinder feeder3121moves the outer cylinder3040mounted on the vibratory table3121aprovided in the outer cylinder feeder3121towards the first transport path3220.

The first transport path3220transports the outer cylinder3040in the first transport direction (direction labeled “C1” inFIGS. 38 and 39) lying along the longitudinal direction of the outer cylinder3040. The first transport path3220is inclined in such a manner that the outer cylinder3040slides down the first transport path3220. Further, since the first transport path3220is located at a position on the downstream side of the orienting mechanism3170, the first transport path3220transports the outer cylinder3040that has been oriented by the orienting mechanism3170. As has been described above, the orienting mechanism3170orients the outer cylinder3040in such a manner that the rear end part of the outer cylinder3040drops before the leading-end part. Therefore, the outer cylinder3040will move on the first transport path3220with the leading-end part of the outer cylinder3040being located on the upstream side the rear-end part.

The second transport path3230is a part that is connected to the terminal end part of the first transport path3220and receives and transports the outer cylinder3040that has traveled on the first transport path3220from the first transport path3220. The second transport path3230is, in a similar manner to the first transport path3220, inclined in such a manner that the outer cylinder3040slides down the second transport path3230. The second transport path3230extends towards the assembling conveyor3110. Therefore, the outer cylinder3040slides down the second transport path3230and moves towards the assembling conveyor3110. The outer cylinder3040that has slid down the second transport path3230is passed to an outer cylinder setting part3123which will be described later and set on the assembling conveyor3110by the outer cylinder setting part3123.

As shown inFIGS. 38 and 39, the second transport path3230is formed in such a manner that it intersects with (specifically, so as to be perpendicular to) the first transport path3220. Therefore, the second transport direction (direction labeled “C2” inFIG. 39) in which the second transport path3230transports the outer cylinder3040intersects (is perpendicular to) the first transport direction. In other words, the second transport path3230transports the outer cylinder3040received from the first transport path3220in the second transport direction that intersects with (is perpendicular to) the longitudinal direction of the outer cylinder3040.

In the following description, the purpose of providing the direction in which the second transport path3230transports the outer cylinder3040(second transport direction) in such a manner that it intersects (is perpendicular to) the direction in which the first transport path3220transports the outer cylinder3040(first transport direction) will be described.

As shown inFIGS. 38 and 39, there is a case where the outer cylinders3040accumulate in the second transport path3230. This is because the number of outer cylinders3040passed from the first transport path3220to the second transport path3230per unit time is greater than the number of outer cylinders3040passed from the second transport path3230to the outer cylinder setting part3123per unit time. Now, assuming a case in which the second transport path3230transports the outer cylinders3040in the direction lying along the longitudinal direction of the outer cylinder3040, from the reason described above, the outer cylinders3040will accumulate in the direction lying along the longitudinal direction of the outer cylinder3040on the second transport path3230(that is to say, the outer cylinders3040accumulate in a longitudinally aligned state). Also, by means of the orienting mechanism3170, the outer cylinder3040is oriented in such a manner that it travels on the first transport path3220with the leading-end part of the outer cylinder3040being located upstream of the rear-end part in the first transport direction. As a result, if the outer cylinders3040accumulate on the second transport path3230in a longitudinally aligned manner, the outer cylinders3040will be mutually connected on the second transport path3230.

Explaining in detail, among the outer cylinders3040accumulated on the second transport path3230, if we focus on the neighboring two outer cylinders3040, the rear-end part of the outer cylinder3040at the upstream side is caught in the leading-end opening3043of the outer cylinder3040at the downstream side (a so-called jamming). This jamming occurs when the plurality of petaloid parts3044provided on the downstream side outer cylinder3040inclines outwards and the leading-end opening3043is broadened, and the rear-end part of the outer cylinder3040on the upstream side easily get caught in such rear-end opening3045.

Whereas in the present embodiment, the outer cylinders3040are accumulated on the second transport path3230in a side-by-side manner. Therefore, the jamming does not occur on the second transport path3230and the outer cylinders3040can be properly accumulated on the second transport path3230. As shown inFIGS. 38 and 39, the outer cylinders3040accumulated on the second transport path3230are in mutually the same orientation. This is because the outer cylinders3040travels on the first transport path3220with the same orientation oriented by the orienting mechanism3170and passed to the second transport path3230while keeping the same orientation.

The starting-end part of the second transport path3230(i.e., the upstream end part of the second transport path3230in the second transport direction) is connected to the terminal end part of the first transport path3220via a stepped part and is located at a position lower than the terminal end part of the first transport path3220(for example, seeFIG. 42). Therefore, the outer cylinder3040that has slid down the first transport path3220drops after reaching the terminal end of the first transport path3220and is received by the starting end part of the transport path3230. In other words, the starting end part of the second transport path3230includes a receiving part3231that receives the outer cylinder3040that has traveled (slid down) the first transport path3220from the first transport path3220. As will be described later, the receiving part3231of the present embodiment is capable of holding a single outer cylinder3040received from the second transport path3230.

Further, the second transport path3230includes side walls3232and3233at both end parts in the direction intersecting the second transport direction (the first transport direction). The side walls3232and3233extends from the upstream side part of to the downstream side part the second transport path3230and stands substantially upright. The outer cylinder3040on the second transport path3230travels on the second transport path3230in a state that it is held between the side walls3232and3233. The gap between the side walls3232and3233is somewhat longer than the length between the leading-end part and the rear end part of the outer cylinder3040while the petaloid parts3044are open (specifically, approximately 66 mm) and is approximately 80 mm in the present embodiment. (SeeFIG. 42).

As shown inFIG. 38, among the side walls3232and3233, in the side wall3232formed at the end part (hereinafter referred to as one-end part) at the side where the outer cylinder3040is passed from the first transport path3220to the receiving part3231in the first transport direction, an inlet3232ais formed that guides the outer cylinder3040that has traveled on the first transport path3220into the receiving part3231.

On the other hand, the end part (hereinafter referred to as other-end part) opposite to the side to which the outer cylinder3040is passed to the receiving part3231, an outlet3233ais formed that discharges the outer cylinder3040out of the second transport path3230. From this outlet3233a, the outer cylinder3040received by the receiving part3231while the outer cylinder3040is on the receiving part3231(that is to say, the outer cylinder3040that the receiving part3231which is already holding the outer cylinder3040has newly received) is discharged. It is to be noted that either of the inlet3232aand outlet3233ais provided at the starting-end part of the second transport path3230and is located at substantially the same position in the second transport direction.

The third transport path3240is a part connected to the starting-end part of the second transport path3230and receives and transports the outer cylinder3040discharged out of the second transport path3230through the above-mentioned outlet3233a. The third transport path3240is, in a similar manner to the first transport path3220and the second transport path3230, inclined in such a manner that the outer cylinder3040slides down the third transport path3240. Further, the third transport path3240extends from the outlet3233ato the base part of the vibratory table3121aof the outer cylinder feeder3121. Therefore, the outer cylinder3040that is discharged out of the second transport path3230through the outlet3233ais returned to the outer cylinder feeder3121by sliding on the third transport path3240and will travel again on the transfer path3122from the transport path3122.

The outer cylinder setting part3123receives the outer cylinder3040that has slid down the second transport path3230from the second transport path3230and sets the outer cylinder3040on the assembling conveyor3110. In detail, the outer cylinder setting part3123mounts the outer cylinder3040received from the second transport path3230on the mount3160placed on the assembling conveyor3110.

As shown inFIGS. 40A and 40B, the outer cylinder setting part3123includes an outer cylinder receiving table3123aand a rotator mechanism (not shown) that rotates the outer cylinder receiving table3123a.FIGS. 40A and 40Bare diagrams showing the outer cylinder setting part3123. The outer cylinder receiving table3123ais located at a position adjacent to the terminal-end part of the second transport path3230in the second transport direction. The outer cylinder receiving table3123ais located below the terminal end of the second transport path3230. The outer cylinder receiving table3123areceives the outer cylinder3040dropped from the terminal end part of the second transport path3230. It is to be noted that the number of outer cylinders that the outer cylinder receiving table3123acan receive is one.

As shown inFIG. 40A, the outer cylinder receiving table3123areceives the outer cylinder3040in a state that its longitudinal direction lying along the horizontal direction. After receiving the outer cylinder3040, the outer cylinder receiving table3123arotates in such a manner that the longitudinal direction of the outer cylinder receiving table3123ainclines against the horizontal direction as shown inFIG. 40B. Thus, the outer cylinder3040on the outer cylinder receiving table3123awill slide down on the outer cylinder receiving table3123a. At this time, the outer cylinder3040slides down with the rear-end first (in other words, the outer cylinder receiving table3123arotates in such a manner that the outer cylinder3040slides down with its rear-end first). At the front of the lower-end part of the outer cylinder receiving table3123ain an inclined state, the mount3160is in a stand-by state. The outer cylinder3040that has slid down the outer cylinder receiving table3123ais fitted into a circular hole3161of the mount3160and is mounted on the mount3160.

Now, the structure of the orienting mechanism3170will be described with reference toFIGS. 41A to 41C.FIG. 41Ais a diagram showing the position at which the orienting mechanism3170is provided.FIG. 41Bis a plan view of the orienting mechanism3170.FIG. 41Cis a diagram showing how the outer cylinder3040passes through the hole3171in the orienting mechanism3170.

As shown inFIG. 41A, the orienting mechanism3170of the present embodiment is a flat plate provided at the opening3211of the drop chute3210and has substantially the same size as the opening3211. As shown inFIG. 41B, the orienting mechanism3170includes a hole3171formed through which the outer cylinder3040may pass and a pair of first protruded parts3172and a pair of second protruded parts3173protruding inwardly into the hole3171.

The hole3171is a rectangular hole3171and is formed with a size slightly larger than the contour of the outer cylinder3040. The outer cylinder3040that has traveled on the guide path3200is input into the drop chute3210by passing through the hole3171. It is to be noted that as shown inFIG. 41B, the outer cylinder3040passes through the hole3171in such a manner that the longitudinal direction of the outer cylinder3040lies along the longitudinal direction of the hole3171.

The pair of first protruded parts3172is located at one-end side in the longitudinal direction of the hole3171and is formed in such a manner that each of the first protruded parts3172opposes each other. The pair of second protruded parts3173is located at the other-end side in the longitudinal direction of the hole3171and is formed in such a manner that each of the second protruded parts3173opposes each other. As shown inFIG. 41C, the gap between the pair of first protruded parts3172and the gap between the pair of second protruded parts3173are greater than the external diameter of the minor diameter part3042of the outer cylinder3040and is smaller than the external diameter of the major diameter part3041. The external diameter of the annular rib3046of the outer cylinder3040is greater than the gap between the pair of first protruded parts3172and the gap between the pair of second protruded parts3173. Accordingly, a part of the outer cylinder3040where the major diameter part3041and the annular rib3046are formed cannot pass between the pair of first protruded parts3172and between the pair of second protruded parts3173. Whereas, the minor diameter part3042can pass between the pair of first protruded parts3172and between the pair of second protruded parts3173.

Now, the positional relationship between the outer cylinder3040that passes through the hole3171and the first protruded part3172and the second protruded part3173will be described. When the outer cylinder3040passes through the hole3171in a state shown inFIG. 41C, the first protruded part3172and the second protruded part3173are located at positions that do not come into contact with the annular rib3046in the longitudinal direction of the hole3171. The first protruded part3172is located at a position that comes into contact with the major diameter part3041(specifically, a part closer to the rear-end side than the petaloid part3044). Therefore, the first protruded part3172is located at a position where the major diameter part3041cannot pass through the pair of first protruded parts3172. On the other hand, the second protruded part3173is located at a position where the minor diameter part3042passes through the pair of second protruded parts3173.

When the outer cylinder3040passes through the hole3171under such a positional relationship, the major diameter part3041cannot pass between the pair of first protruded parts3172and the minor diameter part3042can pass between the pair of second protruded parts3173. Thus, the rear-end part of the outer cylinder3040will drop first. Thereafter, the outer cylinder3040inclines in such a manner that the rear end is located below the leading end. Thereby, the leading-end part of the outer cylinder3040will pass through the central part (between the pair of first protruded parts3172and the pair of second protruded parts3173) in the longitudinal direction of the hole3171. As a result, the rear-end part of the outer cylinder3040drops through the drop chute3210before the leading-end part. Therefore, the outer cylinder3040proceeds from the rear-end part into the first transport path3220and travels on the first transport path3220with the leading-end part of the outer cylinder3040being situated on the upstream side than the rear-end part in the first transport direction.

On the other hand, when the outer cylinder3040passes through the hole3171with an orientation opposite to the orientation shown inFIG. 41C(the outer cylinder3040shown inFIG. 41Cis inverted), the minor diameter part3042passes between the pair of first protruded parts3172and the major diameter part3041cannot pass between the pair of second protruded parts3173. Therefore, in the above-mentioned case, the outer cylinder3040drops through the drop chute3210with its rear-end part prior to the leading-end part. Thus, the outer cylinder3040travels on the first transport path3220with the leading-end part being situated on the upstream side of the rear-end part in the first transport direction.

—Structure of Discharging the Outer Cylinder3040Out of the Second Transport Path3230—

In the present embodiment, as has been described above, the outer cylinders3040may accumulate on the second transport path3230. That is to say, because the outer cylinders3040are filled in from the starting end of the second transport path3230to the terminal end thereof, there may be a case where the outer cylinders3040cannot be fitted in anymore on the second transport path3230. (That is to say, the outer cylinders3040may stuff up on the second transport path3230). Therefore, the outer cylinders3040that are newly received by the receiving part3231while the outer cylinders3040are accumulated from the starting end to the terminal end of the second transport path, are discharged (expelled) from the second transport path3230.

Before explaining the structure of discharging the outer cylinders3040out of the second transport path3230, the second transport path3230will be explained again with reference toFIGS. 42 to 44B.

FIG. 42is an enlarged view of the area labeled “Y” inFIG. 38.FIG. 43is a diagram showing the positional relationship in the vertical direction between the first transport path3220, the second transport path3230and the third transport path3240and viewing such positional relationship in the direction of arrow A shown inFIG. 42.FIGS. 44A and 44Bare diagrams showing the state in which the receiving part3231receives the outer cylinder3040and viewing such a state in the direction of arrow B shown inFIG. 42.

The second transport path3230includes the above-mentioned receiving part3231at its starting-end part. As shown inFIG. 42, the second transport path3230includes a restricting plate3234provided at the downstream side of the receiving part3231in the second transport direction. This restricting plate3234restricts the outer cylinders3040on the second transport path3230in such a manner that each of the outer cylinder3040does not pile up on other outer cylinders3040. In detail, the gap between the lower surface of the restricting plate3234and the bottom surface of the second transport path3230is slightly longer than the external diameter of the leading-end part of the outer cylinder3040(specifically, approximately 15 mm). The outer cylinder3040received by the receiving part3231passes between the lower surface of the restricting plate3234and the bottom surface of the second transport path3230when traveling on the second transport path3230. As a result, when the outer cylinders3040accumulate on the second transport path3230, each of the outer cylinders3040will accumulate without piling up on other outer cylinders3040.

A part of the restricting plate3234that is situated at the most upstream side in the second transport direction is spaced apart from the starting end of the second transport path3230(upstream side in the second transport direction) with a distance slightly greater than the external diameter of the major diameter part3041of the outer cylinder3040. On the other hand, the receiving part3231is located between the starting end of the second transport path3230and the restricting plate3234in the second transport direction. That is to say, the receiving part3231of the present embodiment is a space formed between the starting end of the second transport path3230and the restricting plate3234in the second transport direction. The receiving part3231has a width, in the second transport direction, capable of accommodating a single outer cylinder3040(seeFIG. 42). It is to be noted that it is not necessary to provide the restricting plate3234.

As shown inFIG. 43, the receiving part3231of the present embodiment is a recess provided between the terminal end part of the first transport path3220and the starting-end part of the third transport path3240. That is to say, the bottom surface of the starting-end part of the second transport path3230is located at a position lower than the bottom surface of each of the terminal end part of the first transport path3220and the starting-end part of the third transport path3240.

The side wall3232at the one-end part of the second transport path3230(the end part on the side where the outer cylinder3040is passed from the first transport path3220to the receiving part3231in the first transport direction) includes, as has been described above, an inlet3232aformed thereon. As shown inFIG. 42, the inlet3232ais a substantially rectangular cutaway part (hereinafter, also referred to as a one-end cutaway part) formed on the upstream side end part of the side wall3232in the second transport direction. The first transport path3220extends to the one-end cutaway part. It is to be noted that the lateral width of the one-end cutaway part is equal to the lateral width of the terminal end part of the first transport path3220and is specifically approximately 33 mm.

The outer cylinder3040that has slid down on the first transport path3220to the one-end cutaway part drops at the stepped part formed under the one-end cutaway part. A height of the stepped part formed under the cutaway part is a height of a part of the one-end part side wall3232of the second transport path3230that is located under the one-end cutaway part (that is, the inlet3232a). In the present embodiment, the height is greater than the external diameter of the leading-end part of the outer cylinder3040(that is, the external diameter of the major diameter part3041) and is less than double the external diameter (specifically, approximately 20 mm).

As has been described above, on the side wall3233at the other end part of the second transport path3230(the end part opposite to the side where the outer cylinder3040is passed from the first transport path3220to the receiving part3231in the first transport direction), the outlet3233ais formed. As shown inFIG. 42, the outlet3233ais also a substantially rectangular cutaway part (hereinafter, also referred to as an other-end cutaway part) formed on the upstream side end part of the side wall3233in the second transport direction. The third transport path3240extends from the other-end cutaway part. It is to be noted that the lateral width of the other-end cutaway part is equal to the lateral width of the starting-end part of the third transport path3240and is specifically approximately 30 mm.

As shown inFIG. 42, a part of the side wall3233at the one-end part of the second transport path3230that is located under the other-end cutaway part forms a stepped part. A height of the stepped part is less than the external diameter of the leading-end part of the outer cylinder3040(that is, the external diameter of the major diameter part3041) (specifically, approximately 8 mm).

With the above-mentioned structure, the recess that serves as the receiving part3231receives the outer cylinder3040that has slid down on the first transport path3220. Also, the recess has a depth in the vertical direction which is capable of holding (keeping inside the recess) a single outer cylinder3040. That is to say, the outer cylinder3040that slides down on the first transport path3220while there is no outer cylinder3040in the recess drops in the recess and will be held in the recess.

Referring toFIG. 44A, a mechanism of holding the outer cylinder3040in the recess will be described. The outer cylinder3040that has slid down on the first transport path3220while there is no outer cylinder3040drops into the recess in a state where it still maintains a momentum acquired by sliding down on the first transport path3220. It is to be noted that the outer cylinder3040drops into the recess in a state where the longitudinal direction of the outer cylinder3040is substantially parallel to the first transport direction (in other words, in a state substantially perpendicular to the second transport direction). The outer cylinder3040that has dropped into the recess (that is, the outer cylinder3040received by the recess) is caught by the side wall3233formed at the other end part of the second transport path3230and is retained in the recess. In other words, the side wall3233formed at the other end part of the second transport path3230retains the outer cylinder3040that has slid down on the first transport path3220while there is no outer cylinder3040in the recess into the recess.

In detail, the side wall3233formed at the other end part of the second transport path3230includes a retaining part3233bbelow the other-end cutaway part (that is, the outlet3233a). This retaining part3233bcatches the outer cylinder3040that has slid down on the first transport path3220while there is no outer cylinder3040in the recess. Then, the outer cylinder3040caught by the retaining part3233blooses the momentum acquired by sliding on the first transport path3220and is retained in the recess.

The outer cylinder3040is oriented by the orienting mechanism3170and travels on the first transport path3220in a state where the leading-end part of the outer cylinder3040is located in the upstream side of the rear-end part in the first transport direction. Thus, when the outer cylinder3040is caught in the retaining part3233b, the rear end of the outer cylinder3040may collide with the retaining part3233b. If the leading end of the outer cylinder3040collides with the retaining part3233b, the petaloid part3044provided at the end part of the leading-end side will bend inwardly. Since the leading-end opening3043is narrowed if the petaloid part3044is bent inwardly, there arises a disadvantage that it becomes difficult to insert the tampon main body3020or inner cylinder3050during the step of inserting the tampon main body3020or inner cylinder3050into the outer cylinder3040. Whereas, in the present embodiment, such a disadvantage can be overcome since the rear end of the outer cylinder3040collides with the retaining part3233b.

The outer cylinder3040that is retained in the recess serving as the receiving part3231moves to the downstream side of the second transport path3230as the outer cylinder3040located on the more downstream side in the second transport path3230moves on the second transport path3230. Thus, there will be no outer cylinder3040in the recess and the outer cylinder3040that is received by the recess thereafter will be retained in the recess.

The outer cylinder3040moves on the second transport path3230while being restricted by the sidewalls3232and3233provided on the second transport path3230. Specifically, the side wall3232formed on the other end part of the second transport path3230includes a portion adjacent to the retaining part3233bin the second transport direction (hereinafter, an adjacent part3233c). As shown inFIG. 42, the height of the adjacent part3233cis greater than the external diameter of the leading-end part of the outer cylinder3040. Also, the side wall3232formed on the one end part of the second transport path3230includes a part opposing the adjacent part3233c(hereinafter, an opposing part3232b). As shown inFIG. 42, the height of the opposing part3232bis greater than the external diameter of the leading-end part of the outer cylinder3040. Thus, the outer cylinder3040travels between the adjacent part3233cand the opposing part3232bwhen traveling on the second transport path3230. Thereby, the outer cylinder3040traveling on the second transport path3230is prevented from falling off from the second transport path3230.

On the other hand, the outer cylinder3040that has slid down on the first transport path3220when there is the outer cylinder3040in the recess serving as the receiving part3231is discharged out of the second transport path3230through the outlet3233a. That is to say, the outer cylinder3040received by the recess while the outer cylinders3040are accumulated from the starting end to the terminal end of the second transport path3230passes by the recess and is passed to the third transport path3240through the outlet3233a. This will be described in detail with reference toFIG. 44B. In the description below, the outer cylinder3040that the recess has previously received is referred to as a previous outer cylinder3040and the outer cylinder3040that slides down on the first transport path3220while the previous outer cylinder3040is in the recess (that is, the outer cylinder3040that the recess subsequently receives) is referred to as a subsequent outer cylinder3040.

When the subsequent outer cylinder3040drops into the recess after passing by the inlet3232a, it will be stacked on the previous outer cylinder3040as shown inFIG. 44B. That is to say, the recess serving as the receiving part3231receives the outer cylinder3040that has slid down on the first transport path3220when the previous outer cylinder3040is in the recess (that is, the subsequent outer cylinder3040) in such a manner that it is stacked on the previous outer cylinder3040.

The subsequent outer cylinder3040that is stacked on the previous outer cylinder3040moves in the recess in such a manner that it slides on the previous outer cylinder3040(seeFIG. 42). At this time, the subsequent outer cylinder3040moves in such a manner that the longitudinal direction of the subsequent outer cylinder3040lies along the longitudinal direction of the previous outer cylinder3040. That is to say, even after being received by the recess, the subsequent outer cylinder3040keeps on traveling in the direction that it has slid down on the first transport path3220(that is, the first transport direction). Thereafter, the subsequent outer cylinder3040passes by the outlet3233a. That is to say, the side wall3233formed at the other end part of the second transport path3230discharges the subsequent outer cylinder3040stacked on the previous outer cylinder3040out of the second transport path3230through the outlet3233a.

In detail, the height of the retaining part3233bformed in the side wall3233is less than the external diameter of the leading-end part of the outer cylinder3040. Thus, the retaining part3233bcan retain the previous outer cylinder3040and cannot retain the subsequent outer cylinder3040that is stacked on the previous outer cylinder3040at the same time. Therefore, since the subsequent outer cylinder3040keeps on moving in the recess serving as the receiving part3231while maintaining the momentum acquired by sliding down on the first transport path3220, it will go over the retaining part3233band is passed to the third transport path3240. (That is to say, it is discharged out of the second transport path3230through the other-end cutaway part.)

Then, the subsequent outer cylinder3040discharged out of the second transport path3230will be returned to the outer cylinder feeder3121(specifically, the bottom part of the vibratory table3121aprovided in the outer cylinder feeder3121) by the third transport path3240(SeeFIGS. 38 and 39). In other words, the outer cylinder3040discharged out of the second transport path3230will be transported towards the first transport path3220again by the outer cylinder feeder3121and circulates between the outer cylinder feeder3121and the transport path3122until it moves on the second transport path3230.

—Effectiveness of Assembling Apparatus3100of the Present Embodiment—

According to the assembling apparatus3100of the present embodiment, as has been described above, when the supplying mechanism3120supplies the outer cylinder3040, the outer cylinder3040received by the receiving part3231when there is no outer cylinder3040in the receiving part3231is retained in the receiving part3231by the side wall3233formed on the other end part of the second transport path3230. On the other hand, the outer cylinder received by the receiving part3231when there is the outer cylinder3040in the receiving part3231is discharged out of the second transport path3230through the outlet3233aformed in the side wall3233. Thus, the outer cylinder3040can be supplied properly.

Hereinafter, the effectiveness of the assembling apparatus3100of the present embodiment will be described with reference toFIG. 45.

FIG. 45is a diagram showing the comparison example for explaining the effectiveness of the assembling apparatus3100of the present embodiment.

Because of the reasons described above, the outer cylinders3040may accumulate on the second transport path3230in a side-by-side manner. Further, if the outer cylinders3040accumulate from the starting end to the terminating end of the second transport path3230, the outer cylinder3040cannot be accommodated on the second transport path3230anymore. That is to say, the outer cylinder3040which the receiving part3231has received when there is the outer cylinder3040in the receiving part3231cannot be accommodated on the second transport path3230any more.

As for the outer cylinders3040that cannot be accommodated on the second transport path3230any more, as shown inFIG. 45, the outer cylinders3040are gradually piled up before the receiving part3231(that is to say, at the terminating end part of the first transport path3220). At this time, the outer cylinders3040pile up in the direction lying along the longitudinal direction of the outer cylinder3040. Further, the outer cylinder3040is oriented by the orienting mechanism3170in such a manner that it travels on the first transport path3220in a state where the leading-end part of the outer cylinder3040is situated on the upstream side than the rear-end part in the first transport direction. As a result, the outer cylinders3040that have piled up before the receiving part3231will be joined with each other, as shown inFIG. 45. That is to say, the above-mentioned jamming occurs before the receiving part3231. With the outer cylinders3040being joined to each other, each outer cylinder3040cannot be supplied individually and thus each of the outer cylinders3040will not be properly set on the assembling conveyor3110. As a result, the manufacturing speed of the tampon3010may be lowered.

On the contrary, according to the present embodiment, when there is a spatial allowance for accommodating the outer cylinders3040on the second transport path3230(that is to say, when there are no outer cylinders3040on the receiving part3231), the outer cylinder3040that is passed from the first transport path3220is retained in the receiving part3231. On the other hand, the outer cylinder3040that was passed when the outer cylinders3040cannot be accommodated on the second transport path3230anymore (that is to say, when there are the outer cylinder3040in the receiving part3231) is discharged out of the second transport path3230.

As has been described above, in the present embodiment, depending on the state in which how the outer cylinders3040are accommodated on the second transport path3230, the outer cylinder3040newly passed to the second transport path3230from the first transport path3220can be transported to a proper transport destination. As a result, the outer cylinders3040can be avoided from being piled up before the receiving part3231and thus the problem illustrated inFIG. 45, in other words the jamming in front of the receiving part3231, can be eliminated. Therefore, with the assembling apparatus3100of the present embodiment, the outer cylinders3040can be appropriately supplied individually and the tampon3010can be manufactured efficiently.

It is to be noted that in the present embodiment, the internal diameter of the leading-end part of the outer cylinder3040(that is to say, the major diameter part3041) is greater than the external diameter of the rear-end part (that is to say, the minor diameter part3042). In such a case, the rear-end part of the other outer cylinder3040can be easily caught into the leading-end part of the outer cylinder3040and thus may easily cause the above-mentioned jamming. It is to be noted that when the internal diameter of the leading-end part of the outer cylinder3040is the same as or even smaller than the external diameter of the rear-end part, if the petaloid parts3044incline outwards and the leading-end opening3043broadens, the rear-end part may get caught in the leading-end part. That is to say, even if the internal diameter of the leading-end part of the outer cylinder3040is the same as or even smaller than the external diameter of the rear-end part, the jamming could occur and thus the assembling apparatus3100of the present embodiment is effective.

In the present embodiment, each of the first transport path3220and the third transport path3240is inclined in such a manner that the outer cylinder3040slides down on each of them and the receiving part3231is a recess between the first transport path3220and the third transport path3240. With such a structure, the outer cylinder3040that slides down on the first transport path3220when there is the outer cylinder3040in the recess is discharged out of the second transport path3230by using the momentum acquired by sliding down on the first transport path3220. Thus, the outer cylinder3040can be properly discharged out of the second transport path3230without separately providing a device for discharging the outer cylinder3040out of the second transport path3230.

In each of the embodiments described above, the manufacturing method and manufacturing device (assembling apparatus3100) of the present invention has been mainly described, but the above-embodiments are solely for facilitating the understanding of the present invention and by no means regarded as limitations on the present invention. The invention can of course be altered and improved without departing from the gist thereof and equivalents are intended to be embraced therein. Also, the above-mentioned setting values, sizes and configurations, etc., are merely an example provided to show the effect of the present invention and is not to be interpreted as limiting the invention.

In the above-mentioned embodiment, the tampon3010having the inner cylinder3050of a two-tier structure (in other words, extendable inner cylinder3050) as a pushing member has been described, but the present invention is not limited thereto. For example, it can be a tampon3010having the inner cylinder3050with a fixed length (which does not extend or contract).

Also, in the above-mentioned embodiment, although the outer cylinder3040including the major diameter part3041and the minor diameter part3042has been described, the outer cylinder3040may be without the minor diameter part3042. That is to say, the external diameter and the internal diameter may be the same between the leading-end part (one-end part in the longitudinal direction) and the rear-end part (other-end part in the longitudinal direction).

Also, in the above-mentioned embodiment, the outer cylinder3040that has traveled on the second transport path3230is passed from the second transport path3230to the assembling conveyor3110(specifically, the mount3160placed on the assembling conveyor3110) via the outer cylinder setting part3123. That is to say, in the above-mentioned embodiment, the second transport path3230is a part of the transport path3122that is nearest to the assembling conveyor3110, but is not limited thereto. The second transport path3230may be a porition of the transport path3122that is not nearest to the assembling conveyor3110and can be, for example, apart that is midway on the transport path3122.

LIST OF REFERENCE NUMERALS