Abstract:
There is provided a tampon applicator apparatus and method for creating and scoring petals or petal tips of the tampon applicator. The apparatus has a holding element for the tampon applicator, a score device for forming a score line at the base of the petals, and two or more punch devices for creating a petal. There is also provided a vacuum for removing the portions of the tampon applicator that are punched out.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to an apparatus for making a tampon applicator and a method for making same. More particularly, the present invention relates to an apparatus for making a cardboard or paper-like tampon applicator having petal-like segments or petal tips. By this apparatus, the petal-like segments are created with one or more perforation lines at the base of the petal-like segments. The present invention also includes a method of making the tampon applicator using this apparatus.  
         [0003]     2. Description of the Prior Art  
         [0004]     A variety of commercial tampon applicators available on the market are formed from paper, cardboard or other pulp-based materials, such as paperboard or paper laminate (collectively referred to as “cardboard”). Many of these commercial products have petal-like segments or petal-tips at the tampon ejection end of the applicator. In some commercial products, the petals are formed into a dome shape over the leading edge of the pledget. The resulting rounded shape is perceived as easier to insert than the blunt-end tampon applicators known in the art, and the petals also protect the pledget.  
         [0005]     The use of such petal-tip applicators results in an increase in the pressure necessary to open the petals during expulsion of the pledget from the tampon applicator. The user must push the applicator plunger with sufficient force to move the pledget forward to open the petals and then pass over the opened petals. If too much pressure or force is required, the tampon applicator will be less acceptable to the consumer.  
         [0006]     A variety of methods have been employed to address this issue. Most methods involve the partial perforation, score line, or weakening of the cardboard, either at the base of the petal, or at some portion of the petal nearer to the tip. However, the perforation or weakening process requires costly and exacting multiple manufacturing steps. There exists a need for a single apparatus or device to economically and efficiently punch or create petals in the barrel of the cardboard tampon applicator, to add one or more perforation lines at the base of the petals, and to preferably also automatically remove the discarded cardboard pieces.  
       SUMMARY OF THE INVENTION  
       [0007]     It is an object of the present invention to provide an apparatus for making a cardboard tampon applicator having petal-like segments or petal tips.  
         [0008]     It is another object of the present invention to provide such a device that creates the petals and also forms or adds one or more perforation lines at the base of the petals.  
         [0009]     It is still another object of the present invention to provide such a device in which the perforation lines at the base of the petals weaken the petals to allow for a decrease in the force applied to open the petals and expel the pledget from the tampon applicator.  
         [0010]     It is a further object of the present invention to provide for such an apparatus that creates the petals, forms or adds the one or more perforation lines at the base of the petals, and removes discarded cardboard.  
         [0011]     It is a still further object of the present invention to provide a method of making a cardboard or paper-like tampon applicator using the apparatus of the present invention.  
         [0012]     These and other objects and advantages of the present invention are achieved by an apparatus of the present invention that makes a cardboard or paper-like tampon applicator. The apparatus has a holding element, preferably a mandrel die, with a center portion for positioning and securing the tampon applicator with said holding element having more than two radially projecting spokes, a plurality of punch devices positioned on some spokes of the mandrel die, and one or more perforating or score devices positioned on one or more of the other spokes of the mandrel die. Each punch device and each score device has a portion that is adapted to move on its respective spoke toward the positioned tampon applicator to strike the tampon applicator. The apparatus also pneumatically activates the punch elements to form petals on the leading end of the tampon applicator and the perforating or scoring elements to form score lines almost simultaneously. The apparatus also has a vacuum device connected to the lower portion of the hollow mandrel die to suction away unused cardboard from the mandrel die. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     These and other embodiments of the present invention will be appreciated by referring to the drawings  
         [0014]      FIG. 1  is a top view of the tampon applicator apparatus of the present invention;  
         [0015]      FIG. 2  is an exploded view of area A of the tampon applicator apparatus of  FIG. 1 ;  
         [0016]      FIG. 3  is a schematic view of a punch tool and a scoring tool in open position with a cutaway view of a tampon applicator blank on the mandrel die of the tampon applicator apparatus of  FIG. 1 ;  
         [0017]      FIG. 4  is a perspective view of a punch tool for the tampon applicator apparatus of  FIG. 1 ;  
         [0018]      FIG. 5  is a perspective view of a scoring tool for the tampon applicator apparatus of  FIG. 1 ;  
         [0019]      FIG. 6  is a cross-sectional view of the tampon applicator apparatus of  FIG. 2  taken along line  6 - 6 , with the tampon applicator blank in position on the mandrel die;  
         [0020]      FIG. 7  is a cross-sectional view of the tampon applicator apparatus of  FIG. 2  taken along line  7 - 7 , with a scoring tool actuated for holding the tampon applicator blank and scoring the blank; and  
         [0021]      FIG. 8  is a cross-sectional view of the tampon applicator apparatus of  FIG. 2  taken along line  8 - 8 , with a punch tool actuated and the blank held by the scoring element, and unused punched out pieces being vacuumed out of the apparatus. 
     
    
     DESCRIPTION OF THE INVENTION  
       [0022]     Referring to the drawings and, in particular,  FIGS. 1 and 2 , there is shown a tampon applicator apparatus generally represented by reference numeral  10 . Apparatus  10  has a generally circular configuration with mandrel die  20  positioned at its center. Preferably, mandrel die  20  has a body  25  that is generally cylindrical in shape. The body  25  has a cylindrical hollow center portion  21  that extends along the central longitudinal axis of the mandrel die, and several radially extending spokes  23 . Mandrel die  20  with two or more webs or spokes  23 , two or more punch slides  40  aligned with and positioned along several spokes of the mandrel die, and one or more perforation or score slides  70  aligned with and positioned on other spokes of the mandrel die. The apparatus  10  has double acting air cylinders  95  that actuate connection elements  96  that are operatively connected to punch slides  40  and score slides  70 . Air cylinders  95  have air lines  97 , each actuating punch slides  40  and perforation or score slides  70  toward inward or outward directions. Although punch slides  40  and score slides  70  are preferably actuated by air cylinders  95  and air lines  97 , actuation can also be achieved by using cams, electrical means such as an electric motor, or any other suitable actuation means. Apparatus  10  may have a base frame  15  on which mandrel die  20 , connection elements  96  and air cylinders  95  are mounted for positional movement. Base frame  15  is preferably a metal board.  
         [0023]     Referring to  FIG. 3 , body  25  has a lower portion  28 , an upper portion  29  and a step  50  that connects the lower to the upper portion. Referring to  FIGS. 1 and 2 , each spoke  23  has an upper surface  24  with a slide channel  26  therein. Preferably, the number of spokes  23  is six to sixteen. More preferably, the number of spokes  23  is twelve.  
         [0024]     In the discussion that follows, the term “proximal,” will refer to the portion of the structure that is closer to mandrel die  20 . The term “distal” will refer to the portion that is further from mandrel die  20 .  
         [0025]     As shown in  FIGS. 1 through 3 , some spokes  23  have connected thereto, preferably removably, punch slides  40 , while all or some of the remaining spokes have connected thereto, preferably removably, perforation or score slides  70 . The punch slides  40  and score slides  70  are arranged also in a radial configuration on spokes  23  of mandrel die  20 . The arrangement and number of punch slides  40  correspond to the position and number, respectively, of petals desired in the ejection end of a tampon applicator or applicator blank  100 , shown in  FIG. 3 . The number of score slides  70  correspond to the number of separate score lines on the base of the petals in applicator  100 . It should be understood that there can be as little as one score line per petal in the tampon applicator and, thus, just one score slide  70  would be needed for each petal. In a more preferred embodiment, there is a score slide  70  placed on each spoke  23  that does not have a punch slide  40  since the greater the number of perforations or score lines, the less force needed to move the formed petals during the tampon ejection process. As shown in the preferred embodiment of  FIGS. 1 and 2 , punch slides  40  and score slides  70  are on alternating spokes  23  of mandrel die  20 . Thus, each score slide  70  has a corresponding punch slide  40  positioned on the other spoke  23  of mandrel die  20  on the same longitudinal axis. It should be understood that two or more score edges  80  could be on a single score tool  78  to form two circumferentially parallel score lines within the base of the petal in tampon applicator  100 .  
         [0026]     As shown in  FIGS. 2 and 3 , each punch slide  40  has a punch tool  30 . Preferably, punch slide  40  is elongated. Each punch slide  40  is secured to a separate spoke  23 . Each punch tool  30  is connected, preferably removably, to its respective punch slide  40 , by any conventional fastener.  
         [0027]     Each punch slide  40  can be located in respective slide channel  26  in spoke  23 . Each slide channel  26  extends from the distal end of a punch slide  40 , to the mandrel die  20 . The channel  26  provides for sliding movement of punch slide  40 . The distal end of each punch slide  40  is connected to air cylinder connection elements  96  to provide conventional power to move the punch arm in sliding movement in slide channel  26 .  
         [0028]     Referring to  FIGS. 3 and 4 , each punch tool  30  is generally the contour of a petal and has an exterior face  31  that has the contour of a petal in the tampon applicator blank  100 . As shown in  FIG. 7 , punch tool  30  is slightly offset from punch slide  40  so that face  31  projects beyond the body of the punch tool, thereby permitting the face to punch its shape into tampon applicator or applicator blank  100  to separate the cardboard. Tampon applicator  100  then has a separation or space  104  that matches face  31  and thus forms an edge of two adjacent petals  106 .  
         [0029]     Referring to  FIGS. 3 and 5 , each score slide  70  has a score tool  78 . Preferably, score slide  70  is elongated. The distal end of each score tool  78  is connected, preferably removably, by any conventional fastener, to the proximal end of each score slide  70 . Each score slide  70  can slidingly move in its channel  26  in spoke  23  in the direction defined by its longitudinal axis. Similar to each punch slide  40 , the distal end of each score slide  40  is connected by air cylinder connection elements  96 , double acting air cylinder  95  and air lines  97  to an air supply to permit movement of the score slide  70  in channel  26  of its respective spoke  23 .  
         [0030]     Each score tool  78  has a contoured proximal surface  79  that is configured to engage applicator blank  100 . Each proximal surface  79  has a protruding generally contour-shaped perforating or score edge  80  that is configured to radially engage the outside surface of the tampon applicator blank  100 .  
         [0031]     Referring to FIGS.  6  to  8 , tampon applicator apparatus  10  includes a vacuum device, such as a tube  90 . In a preferred embodiment shown in  FIG. 3 , the proximal end of vacuum tube  90  is connected to the bottom end of mandrel die  20 , through an opening in base frame  15 . The proximal end of vacuum tube  90  fits over a bottom opening in mandrel die  20 . Preferably, the distal end of vacuum tube  90  is connected to a vacuum generator device and a receptacle.  
         [0032]     In using tampon applicator apparatus  10 , tampon applicator blank  100  is positioned about cylindrical hollow central portion  21  of mandrel die  20  as shown in  FIG. 3 . The diameter of tampon applicator or applicator blank  100  is similar to the diameter of upper portion  29  of body  25  of mandrel die  20 , while still allowing the tampon applicator blank to fit about the upper surface of the upper portion. As shown in  FIG. 3 , tampon applicator blank  100  is placed about upper portion  29  of body  25  of mandrel die  20  with the blank&#39;s proximal lip resting on step  50  of mandrel die  20 . Step  50  has a width close to the paper thickness of tampon applicator blank  100  that allows for an end of applicator blank  100  to rest on step  50 .  
         [0033]     After tampon applicator blank  100  is positioned onto mandrel die  20 , tampon applicator apparatus  10  is activated. Activation of tampon applicator apparatus  10  results initially in clamping and perforation of tampon applicator blank  100 . As shown in  FIG. 7 , score slides  70  are actuated and all slide about simultaneously towards the upper portion  29  of body  25  of mandrel die  20 . All score tools  78  simultaneously, or approximately simultaneously, strike tampon applicator blank  100  radially. Each score tool  78  produces a separate score line  110  in the cardboard at the location of impact. Preferably, six perforated score lines  110  are created. At the same time, score slides  70  clamp tampon applicator blank  100 , as shown in  FIG. 7 .  
         [0034]     As shown in  FIG. 8 , after a slight delay in timing after perforating or scoring and clamping action, punch slides  40  are actuated. While the clamp is sustained, all punch slides  40  slide simultaneously, or approximately simultaneously, towards the upper portion  29  of body  25  of mandrel die  20 . Each punch tool  30  simultaneously, or approximately simultaneously, strikes tampon applicator blank  100  radially so that each exterior face  31  of each punch tool  30  cuts through the cardboard of the tampon applicator blank to form space  104  and enters an aligned triangle shaped groove  27  in the upper portion  29  of body  25  of mandrel die  20 . Exterior face  31  of punch tool  30  can mate with triangle shaped groove  27  on upper portion  29 , to make a clean punch or space  104  on the surface of applicator blank  100 . This action punches or cuts triangular space  104  in tampon applicator blank  100  that is in the shape of triangle shaped groove  27  behind it. Preferably, six triangular shaped spaces with contoured sides  104  are simultaneously, or almost simultaneously, created. As shown in  FIG. 8 , the punched cardboard pieces  99  are pushed into the hollow tube of mandrel die  20 , and are suctioned away from tampon applicator apparatus  10  through vacuum tube  90 , as air is suctioned into mandrel die  20  through its top opening. Punch tools  30  are withdrawn first, and then score tools  78  are withdrawn away from mandrel die  20 .  
         [0035]     As shown in  FIG. 3 , the base of each of the six triangular shaped holes in tampon applicator blank  100  is proximally located. These spaces  104  create six generally triangular petals  106  in the cardboard at the proximal end of tampon applicator blank  100 . Each score line  110  was formed at the distal end base of each petal  106  as shown in  FIG. 3 . The tampon applicator blank  100  can subsequently undergo further processing to form petals  106  into a domed, tapered, or other shape, and to assemble the remaining components of the tampon.  
         [0036]     The present invention having been thus been described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined in the appended claims.