Patent Publication Number: US-2003233813-A1

Title: Process of making a wrapped tampon

Description:
FIELD OF THE INVENTION  
       [0001] This invention relates to catamenial tampons, and more particularly, process for making a wrapped tampon.  
       BACKGROUND OF THE INVENTION  
       [0002] Current tampon wrappers may or may not comprise tear members to help facilitate opening of the wrapper. As well, the tear members of current tampon wrappers are not consistently placed on the wrappers within a given package. Because of this inconsistency, many consumers may not be aware that there are tear members available to facilitate opening of tampons. The process of the present invention provides wrapped tampons with consistently placed tear members. The process of the present invention may optionally include a step of providing an identification graphics overlying the tear member. The resulting consistently placed tear member and the optional identification graphic act as an indicator of the location of the tear member and will facilitate the consumer in properly exposing the tampon for use.  
       SUMMARY OF THE INVENTION  
       [0003] This invention relates to catamenial tampons, and more particularly, a process for making a wrapped tampon. A continuously moving wrapper material is provided that has a pair opposing longitudinal edges, a longitudinal axis and a width. The material is positioned in a pre-rotational positional position. A tear member is provided and is attached parallel to the longitudinal axis. The wrapper material is folded along the longitudinal axis to overlap the pair of opposing longitudinal edges, which are then sealed together to form a longitudinal seal. The wrapper material is cut to form a length and a pair of opposing transverse edges. The wrapper material is maintained in a pre-determined rotational position. The wrapper material is sealed in one of the transverse edges to form a transverse seal having a width defined by a first end and a second end. A tampon is provided and is inserted into the wrapper material through the unsealed transverse edge, which is then sealed to form a transverse seal having a width defined by a first end and a second end. When the wrapper is sealed the tear member extends into the transverse seal adjacent to the first end. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0004] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the present invention, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which:  
     [0005]FIG. 1 is a block diagram of the process of the present invention.  
     [0006]FIG. 2A is an isometric view showing the orientation of the rotating cam, the rotating shear knife and the slotted drum used in the process of the present invention.  
     [0007]FIG. 2B is a front view showing the orientation of the rotating cam, the rotating shear knife and the slotted drum used in the process of the present invention.  
     [0008]FIG. 3 is a right isometric view of the rotating cam.  
     [0009]FIG. 4 is a plan view of wrapped tampon of the present invention incorporating a wrapper having a pair of opposing transverse seals, a longitudinal axis and a tear member. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0010] All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.  
     [0011] As used herein “compressed” refers to pressing or squeezing together or to reduce in size or volume as if by squeezing. The tampons herein are typically formed by laterally compacting or rolling the pledget such a process results in a compressed structure that is suitable from insertion into the vaginal cavity.  
     [0012] The term “joined” or “attached” as used herein, encompasses configurations in which a first element is directly secured to second element by affixing the first element directly to the second element; configurations in which the first element is indirectly secured to the second element by affixing the first element to intermediate member(s) which in turn are affixed to the second element; and configurations in which first element is integral with second element; i.e., first element is essentially part of the second element.  
     [0013] As used herein the terms “pledget” or “tampon pledget” is intended to be interchangeable and refer to a construction of absorbent material prior to the compression of such construction into a tampon as described above.  
     [0014] As used herein the term “pre-determined rotational position” refers to the orientation of the tear member to the transverse seal such that the tear member is located on or about 3 mm, or typically 2 mm away from the first end of the transverse seal.  
     [0015] The term “rotating cam” refers to one mechanism that is used to maintain the wrapper material is a pre-determined rotational position. The rotating cam has a major diameter, minor diameter and two transitional areas between the major and minor diameter. The major diameter is the portion of the rotating cam that contacts the wrapper material, stabilizes the wrapper material in the pre-determined rotational position, and remains in contact with the wrapper material until it is securely placed into the slotted drum ports. The major diameter is sized such that its face velocity when rotating is equal to the linear speed of the upcoming tube. The major diameter has a radial relief that is sized and shaped approximately equal to the diameter of the wrapper material. The axis of the radial relief is perpendicular to the rotational axis of the rotating cam.  
     [0016] As used herein the term “tampon” refers to any type of absorbent structure that is inserted into the vaginal canal or other body cavities for the absorption of fluid there from, or for the delivery of active materials, such as medicaments, or moisture. Tampons are generally “self-sustaining” in that they will tend to retain their general shape and size before use. The tampon has a withdrawal end opposed to an insertion end. A typical compressed tampon is 40-60 mm long measured from the withdrawal end to the insertion end along the longitudinal axis. A typical compressed tampon is 10-16 mm wide corresponding to the largest cylindrical cross section although the width may vary along the length.  
     [0017] As used herein the terms “vaginal cavity,” “within the vagina” and “vaginal interior,” are intended to be synonymous and refer to the internal genitalia of the human female in the pudendal region of the body. The term “vaginal cavity” as used herein is intended to refer to the space located between the introitus of the vagina (sometimes referred to as the sphincter of the vagina) and the cervix and is not intended to include the interlabial space, including the floor of vestibule. The externally visible genitalia is generally not included within the term “vaginal cavity”.  
     [0018] As used herein, “cm” is centimeter, “dpf” denier per foot, “g” is grams, “gms” is grams per square meter “mm” is millimeters, “ml” is milliliters, “rpm” rate per minute, and “sec” is seconds.  
     [0019] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention.  
     [0020]FIG. 1 is a block diagram of the process of the present invention. A continuously moving wrapper material is provided having a longitudinal axis, a pair of opposing longitudinal edges, and a width. A tear member is provided and may be attached after the wrapper is provided or the tear member may be already attached. Regardless of when it is attached, the tear member is attached parallel to the longitudinal axis. The material is positioned in a pre-determined rotational positioned. The wrapper material is then folded along the longitudinal axis to overlap the pair of opposing longitudinal edges, which are then sealed together to form a longitudinal seal. The wrapper material is cut to form a length and a pair of opposing transverse edges. The wrapper material is typically cut to a length that is longer than the axial length of the tampon. The wrapper material is maintained in a pre-determined rotational position. The wrapper material is sealed on one of the transverse edges of the wrapper material to form a transverse seal having a width defined by a first end and a second end. A tampon is provided and is inserted into the wrapper material through the unsealed opposing transverse edge, which is then sealed to form a transverse seal. When the wrapper is sealed the tear member extends into the transverse seal adjacent to the first end.  
     [0021]FIG. 2A is an isometric view showing the orientation of the rotating cam, the rotating shear knife and the slotted drum in a machine that may be used in the process of the present invention. The wrapper material  22  is feed by a conveyor and in some embodiments of the process of the present invention, the rotating cam  6  is used to maintain the wrapper material in a pre-determined rotational position. The rotating shear knife  8  is used to cut the wrapper material to a length. The rotating cam  6  is located downstream of the rotating shear knife  8 . The rotating cam  6  and rotating shear knife  8  rotate at coordinated speeds (rpm). The rotating cam comes into contact with a tube of wrapper material  22  prior to the cutting with the rotational shear knife  8  and begins pushing the tube of wrapper material on angle into a ports  12 , (as shown in FIG. 2B) on a slotted drum  10 .  
     [0022]FIG. 2B shows the front view shows the ports on the slotted drum  10 . In some embodiments, the tube of wrapper material begins to engage the slotted drum ports  12 , a vacuum port (not shown) in the rotating cam opens and the vacuum maintains the tube of wrapper  22  material in its pre-determined rotational position in the slotted drum ports  12 .  
     [0023]FIG. 3 shows a right isometric view of the rotating cam  6  that may be used to maintain the wrapper material in a pre-rotational position. The rotating cam  6  has a major diameter  14  and a minor diameter  16 , and two transitional areas  18  between the major and minor diameter. The major diameter  14  of the rotating cam  6  has a radial relief  20  that is sized and shaped approximately equal to the diameter of the wrapper material is cut in the major diameter  14  segment. The major diameter  14  segment of the cam is the portion that comes into contact with the wrapper material and stabilizes it.  
     [0024]FIG. 4 shows a plan view of one embodiment of such a wrapped tampon resulting from the process of the present invention. The wrapper material  22  has a length  24  longer than the axial length of the tampon, a pair of opposing transverse seals  28 , a longitudinal axis “L” and a tear member  38 . The transverse seals  28  of the wrapper have a width  32  defined by a first end  34  and second end  36 . The longitudinal seal  30  is oriented parallel to the longitudinal axis “L”. The tear member  38  is oriented parallel to the longitudinal axis “L” and extends into each of the transverse seals  28  adjacent to the first ends  34  of each of said transverse seals  28 . One of said transverse seals  28  is a tear-initiating end.  
     [0025] I. Tampon of the Present Invention:  
     [0026] The tampon of the present invention is comprised of a compressed absorbent material. The tampon has an axial length, a circumference, and an insertion end opposed to a withdrawal end. The tampon may be any suitable size and thickness suitable for insertion in the vaginal cavity of the user. In some embodiments, the absorbent material is generally square or rectangular, but other shapes such as trapezoidal, triangular, hemispherical, chevron and hourglass shaped are also acceptable. A typical size for absorbent material prior to compression may be from about 40 mm to about 100 mm in length and from about 40 mm to about 80 mm in width. In general, the absorbent material is 40 mm to 60 mm in length and from about 50 mm to about 70 mm in width. The typical range for the overall basis weight is from about 150 gms to about 800 gms.  
     [0027] The tampon of the present invention may be constructed from a wide variety of liquid-absorbing materials commonly known in the art and used in absorbent articles such as rayon (including tri-lobal such as GALAXY Rayon (a tri-lobed rayon structure) available as 6140 Rayon from Acordis Fibers Ltd., of Hollywall, England and conventional rayon fibers, and needle punched rayon), cotton (long fibers, short fibers, cotton linters, T-fibers, card strips, comber cotton), or comminuted wood pulp. The materials for the tampon can be formed into a fabric, web, or batt that is suitable for use in the absorbent material by any suitable process such as airlaying, carding, wetlaying, hydroentangling, needling or other known techniques.  
     [0028] If the compressed absorbent member of the present invention is layered, the layers may comprise different materials. For example, in one embodiment, the outer layers may comprise primarily rayon, while the intermediate layer or layers may comprise primarily cotton. Optionally, the entire compressed absorbent member may comprise a uniform or non-uniform blend of materials throughout. In one-layered embodiments each of the layers may comprise essentially 100% of the same material, such as outer layers of 100% rayon and an intermediate layer of 100% cotton. A Super Plus absorbency tampon of the present invention may be made from a pledget comprising about 100% rayon fibers. A Super absorbency or regular absorbency tampon of the present invention may be made from a pledget comprising about 25% cotton and about 75% rayon fibers. A junior absorbency tampon may be made from a pledget comprising about 67% cotton and about 33% rayon fibers.  
     [0029] Pressures and temperatures suitable for compression are well known in the art. Typically, the absorbent material and the fluid wicking overwrap is compacted in the radial direction and optionally in the axially along the longitudinal and lateral axes by any means well known in the art. While a variety of techniques are known and acceptable for these purposes, a modified tampon compressor machine available from Hauni Machines, Richmond, Va., is suitable.  
     [0030] In one embodiment, the tampon of the present invention may comprise a withdrawal means. The withdrawal means will be joined to the tampon and will be graspable for removal after use. The withdrawal means may be joined to any suitable location on the tampon and extends beyond at least the withdrawals end. Any of the withdrawal means currently known in the art may be used as a suitable withdrawal mechanism. In addition, the withdrawal means can take on other forms such as a ribbon, loop, tab, or the like. The withdrawal means may be attached in any suitable manner known in the art including sewing, adhesive attachment, or a combination of known bonding methods.  
     [0031] The tampon of the present invention may be inserted digitally or through the use of an applicator. Any of the currently available tampon applicators may also be used for insertion of the tampon of the present invention. Such applicators of typically a “tube and plunger” type arrangement and may be plastic, paper, or other suitable material. Additionally, a “compact” type applicator is also suitable.  
     [0032] II. The Wrapper of the Present Invention:  
     [0033] The wrapper has a length longer than said axial length of the tampon and a width as greater than the circumference of the tampon. The wrapper of the present invention is typically 130-180 mm in length and 40-80 mm in width. The wrapper has a pair of opposing transverse seals, a longitudinal axis “L” and a tear member. The transverse seals of the wrapper have a width defined by a first end and second end. The transverse seals of the wrapper are 20-40 mm in width. The transverse seal are 1-5 mm in height. The longitudinal seal is oriented substantially parallel to the longitudinal axis “L” and extends into each of said transverse seals. The longitudinal seal may be positioned equidistant from the first end and second end of the transverse seal.  
     [0034] The tear member is oriented substantially parallel to the longitudinal axis “L” and extends into each of the transverse seals adjacent to the first ends of each of said transverse seals. The tear member may be oriented parallel to the longitudinal seal. The tear member may be located about 3 mm from the first ends of the transverse seals. Typically, the tear member may be located within about 2 mm of the first ends of the transverse seals. One of said transverse seals may be a tear-initiating end. The tampon may be oriented such that the withdrawal end or the insertion end of the tampon is oriented within the wrapper adjacent to the tear-initiating end.  
     [0035] The walls of the wrapper can be of any desired thickness, commensurate with the intended use. Generally, the walls are flexible and fluid-impermeable. Typically, the walls of package  2  have a thickness of from about 0.0127 mm (0.5 mil) to about 0.127 mm (5.0 mils). The wrapper can be made of laminates of plastic and paper, or paper fibers with fillers (RFS ECUSTA INC. Pisgah Forest, N.C. 28768). Typically the tear member is attached to the wrapper material when it is received. The tear member may be a bead of glue or a thread.  
     [0036] The wrapper material may optionally have an identification graphic on the opposite side overlaying the tear member. The optional identification graphic may depict the location of the tear member. The optional identification graphic may depict or recite instructions to aid the consumer in using the tear member to properly expose the tampon for use.  
     [0037] III. The Process of Making the Wrapped Tampon:  
     [0038] While several methods of making the tampon of the present invention would be apparent to one of skill in the art in light of the disclosure herein, the previous description in DETAILED DESCRIPTION OF THE INVENTION in conjunction with the accompanying FIG. 1 is one method of making a wrapped tampon of the present invention.  
     [0039] IV. Example of the Process:  
     [0040] In one embodiment of the process, a roll of wrapper material having a longitudinal axis and a width is provided and is unwound. The wrapper material provided has a tear member joined or secured thereto and a pair of opposing longitudinal edges. The wrapper material is positioned in a pre-determined rotational position and placed on a conveyor. The wrapper material is formed over a mandrel along the longitudinal axis to overlap the pair of opposing longitudinal edge and form a continuous tube of wrapper material. The wrapper material with the pair of opposing longitudinal edges is sealed together to form a longitudinal seal by a rotating pair of knurled nip rollers.  
     [0041] Next, the wrapper material is continuously fed through the rotating shear knife that cuts the wrapper material into discrete lengths or wrapper tubes. The wrapper tubes are open at both ends and a fed into a slotted drum with ports formed around its circumference. The control of rotation and the orientation of the tear member on the wrapper tubes can be accomplished by various methods. For example, the slotted drum and the wrapper material may be aligned such that the wrapper tubes are fed straight into the drum, not down, or at an angle. Brushes may be added to press lightly against the wrapper to provide friction to help prevent rotation. Air blow nozzles may help control the wrapper material&#39;s insertion into the slotted drum.  
     [0042] In one embodiment, a rotating cam that is downstream of rotating shear knife is used. The rotating cam is coordinated in speed (rpm) with the knife and the wrapper feeds. This rotating cam maintains the wrapper material in a pre-determined rotational position. The radial relief of the rotating cam comes into contact with a tube of wrapper material prior to the cutting with the rotating shear knife and begins pushing the tube of wrapper material on angle into a port on a slotted drum. As the tube of wrapper material begins to engage the slotted drum ports, a vacuum port in the rotating cam opens and the vacuum positions and maintains the tube of wrapper material in its pre-determined rotational position in the slotted drum port. The wrapper material may be maintained in a pre-determined rotational position by others means.  
     [0043] The slotted drum has multiple ports in which the wrapper tubes are fed and has an indexing motion that moves the drum into multiple phases of the process. The wrapper tubes are fed on while the drum is stationary. Once in the ports of the slotted drum the discrete lengths of wrapper material are held in place by vacuum. The drum indexes and as it does so, one of the transverse edges of the wrapper material is then sealed by a pair knurled nip rollers to form a transverse seal. The transverse seal has a width defined by a first end and a second end. The transverse seal is sealed such that the tear member on the wrapper material extends into the transverse seal adjacent to the first end. A tampon is provided with an axial length, a radial circumference, and an insertion end opposed to a withdrawal end.  
     [0044] As the slotted drum continues to index, the open-ended wrapper is brought in front of nozzle, which houses a tampon. The tampon is inserted into the wrapper material through the unsealed transverse edge. The slotted drum continues to index and the other end of wrapper material is sealed at the opposing transverse edge of the wrapper material by a pair knurled nip rollers to form a transverse seal having a width defined by a first end and a second end. When the wrapper is sealed the tear member is located about 3 mm, or typically 2 mm away from the first ends of the transverse seals.