Abstract:
There is provided a multiple-component tampon applicator formed from at least three separate components. A fingergrip having a reduced cross-section as compared to that of the barrel may be formed such that it is a separate component or is integrally formed with a barrel component. The reduced cross-section fingergrip provides exceptional grippability to the user. The multiple components may be formed from materials including, for example, biopolymer including starches and proteins, cardboard, heat shrink plastic, paper slurry, plastic, plastic tubing, pulp slurry, pulp-molded paper, or any combinations thereof. Prior to assembly of the applicator and prior to loading the barrel component with an absorbent pledget, petals may be formed on the insertion end of the barrel using existing processes and equipment. Alternatively, a separate insertion tip component having petals may be formed. This separate component may then be connected to the barrel component either before or after an absorbent pledget is loaded into the barrel component.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to an insertion device, such as a catamenial tampon applicator. More particularly, the present invention relates to a multiple-component tampon applicator formed from at least three distinct and separate components.  
           [0003]    2. Description of the Prior Art  
           [0004]    The majority of commercial tampon applicators are of approximately uniform cross-section and are formed from only two components, namely a barrel and a plunger. The fingergrip, if any, is formed as an integral part of the barrel component. Some applicators have a fingergrip and a plunger of a cross-sectional area reduced from that of the applicator barrel. This feature has been found not only to render the tampon applicator more grippable, but it is also more aesthetically preferred.  
           [0005]    For current reduced cross-sectional area fingergrip tampon applicators, the tampon pledget must be loaded into the insertion end of the applicator due to the smaller opening at the fingergrip end. Thus, these tampons are restricted to top or insertion end loading. This requires the petals of the applicator, if any, to be post-formed to their final shape after the pledget has been loaded. Post-forming of petals requires the material to be plasticized. Typically, plastic petals are plasticized by heat and are easily shaped by the use of an external forming die.  
           [0006]    On the other hand, cardboard petals are more difficult to plasticize and require the additional use of an internal mandrel. Usual methods involve heating the tip to volatize the water (either existing or supplemental moisture), and then forcing the petal into shape using an internal mandrel in conjunction with the external die. The internal mandrel has a cross-sectional area that is approximately the same as the barrel&#39;s interior, and consequently would not be able to enter through a reduced cross-sectional fingergrip area. Therefore, the necessity of the internal mandrel to shape the petal tip has thus far precluded the manufacture of a reduced cross-sectional fingergrip area on a cardboard applicator.  
           [0007]    Therefore, there is a need for a tampon applicator, and more specifically a cardboard applicator, that can be manufactured such that petal tips can be pre-formed or integrated on the insertion end of the applicator barrel, prior to loading an absorbent pledget, using existing manufacturing processes and equipment.  
         SUMMARY OF THE INVENTION  
         [0008]    It is an object of the present invention to provide a tampon applicator that is assembled from at least three distinct and separate components.  
           [0009]    It is another object of the present invention to provide such a tampon applicator that has a barrel formed from cardboard.  
           [0010]    It is still another object of the present invention to provide such a tampon applicator having a fingergrip with a reduced cross-sectional area compared to that of the applicator barrel.  
           [0011]    It is a further object of the present invention to provide such a tampon applicator having petals at the insertion end of the cardboard barrel prior to loading the barrel with an absorbent pledget.  
           [0012]    It is still a further object of the present invention to provide such a tampon applicator in which the petals are pre-formed using existing processes and equipment.  
           [0013]    It is yet a further object of the present invention to provide such a tampon applicator in which the petals are formed on a separate and distinct insertion tip component that may be connected to a separate barrel component either before or after a pledget is loaded into the barrel component.  
           [0014]    It is still yet a further object of the present invention to provide such a tampon applicator that prior to assembly of the applicator, and prior to loading the barrel component with an absorbent pledget, petals may be formed on the insertion end of the barrel using existing processes and equipment.  
           [0015]    These and other objects of the present invention will be appreciated from a multiple-component tampon applicator formed from at least three separate and distinct components. A separate insertion tip component having petals may be formed. This separate component may then be connected to the barrel component either before or after an absorbent pledget is loaded into the barrel component. Also, a fingergrip may be formed as a separate component or it may be integrally formed with the barrel.  
           [0016]    The multiple components may be formed from materials including, for example, plastic, cardboard, paper slurry, pulp slurry, pulp molded paper, heat shrink plastic, plastic tubing, biopolymers including carbohydrates and proteins, or any combinations thereof. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    [0017]FIG. 1 is an exploded view of a multiple-component applicator having three components that form the tampon applicator of the present invention;  
         [0018]    [0018]FIG. 2 is an exploded view of a multiple-component applicator having four components that form the tampon applicator of the present invention;  
         [0019]    [0019]FIG. 3 is an exploded view of a three-component applicator of the present invention where the barrel component includes the fingergrip;  
         [0020]    [0020]FIG. 4 is a perspective view of an assembled three-piece tampon applicator of FIG. 1;  
         [0021]    [0021]FIG. 5 is a perspective view of a fingergrip component of the tampon applicator of FIG. 1;  
         [0022]    [0022]FIG. 6 is a perspective view of a fingergrip component according to another embodiment of the present invention;  
         [0023]    [0023]FIG. 7 is a perspective view of a three-piece applicator according to yet another embodiment of the present invention;  
         [0024]    [0024]FIG. 8 is a perspective view of several embodiments of fingergrip components having various gripping structures according to the present invention;  
         [0025]    [0025]FIG. 9 is a perspective view of a fingergrip component according to another embodiment of the present invention;  
         [0026]    [0026]FIG. 10 is a perspective view of a fingergrip component according to another embodiment of the present invention;  
         [0027]    [0027]FIG. 11 is a perspective view of a fingergrip component according to another embodiment of the present invention;  
         [0028]    [0028]FIG. 12 is a perspective view of a multiple-component applicator having three components that form one embodiment of a tampon applicator of the present invention;  
         [0029]    [0029]FIG. 13 is a perspective view of the fingergrip and barrel components of FIG. 12 in a heated former; and  
         [0030]    [0030]FIG. 14 is a perspective view of a multiple-component applicator with the barrel and fingergrip formed in the heated former of FIG. 13. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0031]    Referring to the drawings and in particular FIG. 1, a first embodiment of a multiple-component tampon applicator of the present invention is represented generally by reference numeral  10 . One distinguishing feature of this applicator  10  is that instead of being formed from two components, namely, a barrel and a plunger, it is formed from three distinct components. In a preferred aspect of this first embodiment, the three distinct components are barrel  12 , plunger  14 , and fingergrip or fingergrip component  16 .  
         [0032]    The barrel  12  retains its approximately uniform cross-section, thus allowing petals  18  to be formed prior to pledget insertion. The petals  18  can be formed with the assistance of an internal mandrel, if desired.  
         [0033]    Referring to FIG. 2, a second embodiment of the multiple-component tampon applicator according to the present invention is depicted. This applicator  10  is formed from four distinct components. Again, as a preferred aspect of this second embodiment, the preferred components are barrel  12 , plunger  14 , fingergrip  16 , and insertion tip  19 . Petals  18  are formed on insertion tip  19 . As such, an absorbent pledget may be loaded into barrel  12  either before or after insertion tip  19  is connected to barrel  12 .  
         [0034]    Referring to FIG. 3, a third embodiment of the multiple-component applicator of the present invention is shown. This applicator  10  is formed from at least three distinct components, namely, barrel  12 , plunger  14 , and insertion tip  19 . Barrel  12  has a forward end  21 . In this embodiment, fingergrip  16  is integrally formed as part of barrel  12 . An absorbent pledget may be loaded into barrel  12  through forward end  21 , prior to connecting insertion tip  19  to the barrel.  
         [0035]    Barrel  12  of the multiple-component applicator  10  of the present invention may be formed from any suitable material. Suitable materials for forming barrel  12  include, for example, biopolymer, cardboard, heat shrink plastic, paper slurry, plastic, plastic tubing, pulp slurry, pulp-molded paper, or any combinations thereof. Preferably, barrel  12  is formed from cardboard. Barrel  12  may be formed from spiral wound or convolutely wound cardboard.  
         [0036]    Any individual component that forms the multiple-component applicator, and especially barrel  12 , may be internally and/or externally coated with any suitable material to enhance its strength and/or reduce surface friction. Suitable coatings include, for example, cellophane, cellulose, epoxy, lacquer, nitrocellulose, nylon, plastic, polyester, polylactide, polyolefin, polyvinyl alcohol, polyvinyl chloride, silicone, wax, or any combinations thereof. It should also be understood that barrel  12 , while depicted as a single component, may be formed from one or more components, such that when assembled, the one or more components form barrel  12 .  
         [0037]    Plunger  14  may be formed from any suitable material. Suitable materials for forming plunger  14  include, for example, biopolymer, cardboard, heat shrink plastic, paper slurry, plastic, plastic tubing, pulp slurry, pulp-molded paper, or any combinations thereof. Preferably, plunger  14  is formed from cardboard.  
         [0038]    Referring to FIGS. 1 and 2, fingergrip  16 , as a separate component, provides a way to create an applicator having a cardboard barrel with pre-formed petals and, perhaps, a reduced cross-sectional fingergrip area with an accompanying reduced cross-section plunger  14 . Fingergrip  16  has two distinct ends, barrel or forward end  20  having a diameter approximately equal to that of barrel  12 , and plunger or rearward end  22  having a diameter slightly larger than that of plunger  14 . Fingergrip  16  also has channel  26 , which extends axially through the entire length of the fingergrip. Channel  26  has a cross-sectional area slightly larger than that of plunger  14  so as to accommodate the plunger during assembly of applicator  10 . The pledget (not shown) is loaded into barrel  12  through fingergrip or rearward end  24  of the barrel. Petals  18 , if any, on barrel  12  have been pre-formed into their final shape, as in FIG. 1.  
         [0039]    As shown in FIG. 2, when insertion tip  19  and fingergrip  16  are formed as separate components, an absorbent pledget (not shown) may be loaded either through forward end  21  or barrel rearward end  24  of barrel  12 .  
         [0040]    Referring to FIG. 3, when insertion tip  19  is formed as a distinct component, it also allows barrel  12  and fingergrip  16  to be formed as one component. With this configuration, an absorbent pledget may be loaded into barrel  12  through forward end  21 , prior to assembling the multiple-component applicator.  
         [0041]    By way of example, FIG. 4 shows the three-component applicator of FIG. 1 assembled. Once an absorbent pledget (not shown) is loaded into barrel  12 , barrel forward end  20  of fingergrip  16  is connected to barrel  12  at barrel rearward end  24 . Plunger  14  is then inserted into fingergrip plunger end  22  through channel  26 . Alternately, plunger  14  may be loaded into channel  26  of fingergrip  16  prior to the fingergrip being connected to barrel  12 . Fingergrip  16  may be secured permanently to barrel  12  by any conventional method. Preferably, fingergrip  16  is connected to barrel  12  with an adhesive. Outer edge  25  of fingergrip  16  may be of such a size that it creates a continuous surface flush with the outer edge of barrel  12 .  
         [0042]    It should be understood that the multiple-component tampon applicators depicted in FIGS. 2 and 3 may also be assembled according to the same basic tenets set forth for assembling the three-component applicator of FIG. 1. One distinguishing feature of the applicator of FIG. 2 with respect to assembly, is that the absorbent pledget may be loaded into barrel  12  either through forward end  21  or barrel rearward end  24 . Therefore, the order in which the components are assembled may depend on which end of barrel  12  the pledget is loaded. A distinguishing feature of the applicator of FIG. 3, with respect to assembly, is that barrel  12  and fingergrip  16  are formed as one component, therefore, the absorbent pledget must be loaded into barrel  12  through forward end  21 , prior to assembling insertion tip  19  with barrel  12 .  
         [0043]    It should also be understood that each component of the tampon applicator set forth above may be formed from one or more individual parts or sections (i.e. barrel  12 , plunger  14 , fingergrip  16  and/or insertion tip  19  may be formed from one or more individual parts or sections that are connected to form the component) . In addition, it should be understood that while each applicator component is shown above as being discrete and separate from each other, any two or more of the components may be integrally formed and then assembled with the one or more separate components. By way of example, the insertion tip  19 , the barrel  12 , the fingergrip  16 , and/or the plunger  14  may be integrally formed, in any combination. In addition, any component that is made up from two or more parts or sections, as set forth above, may be connected to form that component, prior to connecting with any other individual component to form an assembled applicator  10 . However, the overall applicator will, nonetheless, have at least three components.  
         [0044]    Fingergrip  16  can be formed from any suitable moldable material. Suitable moldable materials include, for example, biopolymer, cardboard, heat shrink plastic, paper slurry, plastic, plastic tubing, pulp slurry, pulp-molded paper, or any combinations thereof. In a preferred embodiment of the present invention, fingergrip  16  is formed from pulp molded paper.  
         [0045]    [0045]FIG. 5 is another embodiment of the present invention. Fingergrip  16  is formed with a connector ring  32  on barrel forward end  20 . Connector ring  32  has a diameter slightly larger than the internal diameter of barrel  12  so that fingergrip  16  can be connected and secured to barrel  12  by interference fit.  
         [0046]    [0046]FIG. 6 is another embodiment of the present invention. Connector ring  32  may be formed with one or more tabs, ridges and/or slots  34 . One or more tabs, ridges and/or slots  34  can interlock with corresponding tabs, ridges and/or slots (not shown) formed on the inner surface of barrel  12 , thus securing fingergrip  16  to barrel  12 . The one or more tabs, ridges and or slots may be formed on external and/or internal surfaces.  
         [0047]    [0047]FIG. 7 is another embodiment of the present invention. In this embodiment, fingergrip  16  is formed from a heat-shrinkable material  36  that has an initial diameter larger than the outer diameter of barrel  12 , and shrinks to a diameter at least as small as plunger  14 . Heat-shrinkable material  36  at barrel end  20  is shrunk to fit the outside of barrel  12  snugly. The union between heat-shrinkable material  36  and barrel  12  can be reinforced with an adhesive. Plunger or rearward end  22  of fingergrip  16  is shrunk so that it is just larger than the outside diameter of plunger  14 .  
         [0048]    The fingergrip  16  may be formed with any number and/or configuration of gripping structures, to further enhance the applicator&#39;s grippability. Fingergrip  16  may be smooth or, more preferably, may include one or more patterned or textured structures extending above and/or below the surface of the fingergrip.  
         [0049]    The gripping structures may include, for example, one or more abrasive materials, embossments, grooves, high wet coefficient of friction materials, lances, pressure sensitive adhesives, protuberances, slits, treads, or any combinations thereof. In addition, the gripping structures may be formed in any shape, including, for example, arc, circle, concave, cone, convex, diamond, line, oval, polygon, rectangle, rib, square, triangle, or any combinations thereof.  
         [0050]    Referring to FIG. 8, by way of example, several different fingergrip embodiments having various gripping structures are depicted. FIG. 8A depicts fingergrip  16  with one or more bands  38  circumferentially disposed around fingergrip rearward end  22 . FIG. 8B depicts fingergrip  16  with one or more dot-like structures  40  disposed circumferentially around fingergrip rearward end  22 . FIG. 8C depicts fingergrip  16  with one or more circular structures  42  disposed circumferentially around fingergrip rearward end  22 . FIG. 8D depicts fingergrip  16  with two or more wavy bands  44  disposed circumferentially around fingergrip rearward end  22 .  
         [0051]    It should be understood that the gripping structures may be arranged circumferentially around fingergrip  16  in any pattern suitable for forming a gripping area. For example, the gripping structures can form a distinct pattern, such as, rows, columns or may be formed intermittently with breaks in structure or in any random order or pattern.  
         [0052]    [0052]FIG. 9 is another embodiment of the present invention. In this embodiment, fingergrip rearward end  22  may be formed with a circumferentially flared or ridge-like structure end  46 , to further enhance the gripping characteristics of the applicator.  
         [0053]    [0053]FIG. 10 is another embodiment of the present invention. In this embodiment, fingergrip rearward end  22  is formed with a stepped taper to further enhance the gripping characteristics of the applicator.  
         [0054]    [0054]FIG. 11 is another embodiment of the present invention. In this embodiment, fingergrip rearward end  22  may be formed with a knob-like structure  48  to further enhance the gripping characteristics of the applicator.  
         [0055]    Any combinations of the features depicted in FIGS. 8 through 11, and described above, are possible as well. In addition, the gripping structures could be raised, depressed, or any combination thereof, with respect to the surface of the fingergrip area. The gripping structures can be formed in any shape, in any number, and in any pattern or configuration suitable for forming an enhanced gripping area on fingergrip  16 . As such, it should be clear that the present invention is in no way limited by those features depicted or described above.  
         [0056]    It is also understood that the cross-section of barrel  12 , plunger  14 , fingergrip  16  and insertion tip  19  can be circular, oval, polygonal or elliptical. Also, insertion tip  19  can be tapered, elliptical, dome-shaped or flat. Barrel  12  can be straight, tapered, or curvilinear along its length.  
         [0057]    Referring to FIGS. 12 through 14, a method of assembling a multiple component tampon according to another embodiment of the present invention is depicted. Applicator  10  has independent or discrete barrel  12 , plunger  14  and fingergrip  16 . To assemble the components, adhesive  50  is applied to the fingergrip barrel end  20 . As depicted in FIG. 13, fingergrip  16  is inserted into cavity  62  of heated shaper  64 . Mandrel  60  is inserted into fingergrip  16  housed in cavity  62 . Barrel  12  is inserted over mandrel  60 . The barrel  12  and fingergrip  16  are allowed to remain in position in heated shaper  64  for about 1 to 20 seconds and more preferably 5 to 10 seconds.  
         [0058]    Referring to FIG. 14, when removed from the mandrel  60  and heated shaper  64 , the fingergrip  16  is connected to barrel  12  at tapered rearward end  66 . Plunger  14  may then be inserted into fingergrip  16 .  
         [0059]    The foregoing specification and drawings are merely illustrative of the present invention and are not intended to limit the invention to the disclosed embodiments. Variations and changes, which are obvious to one skilled in the art are intended to be within the scope and nature of the present invention, which is defined in the appended claims.