Patent Description:
Tampons are well known in the art and are used for feminine hygiene. As such, many tampon manufacturing methods and apparatuses have been disclosed in the prior art. Generally, a distinction is made between folded and rolled tampons. The former has improved absorbent characteristics but possess less strength and are commonly used with an applicator to reduce the chance of tears and other damages to the tampon before insertion. Rolled tampons are slightly less absorbent, but sturdier and can be applied digitally, as opposed to the folded tampons. Furthermore, measures can be taken to increase the absorbency of the rolled tampons.

Tampons comprise a rolled or folded absorbent fiber sheet and a withdrawal string for removal. Tampons are manufactured by rolling or folding multiple-layers. The multiple-layered sheets comprise a layer of absorbent material of a certain length, upon which a strip of web material is bonded which has only a fraction of the length of the layer of the absorbent material, thus creating the multiple-layered sheets.

It is desired to attain a maximal production speed, but one recurring problem is that the machines are often limited in speed during the head-shaping step, as most machines exploit a heating press to impart pressure and heat onto the introductory end of the tampon. These machines are not efficient enough as it requires several hits to correctly shape a tampon head and these machines are often subject to mechanical failure with parasite melting of the thermoplastic film onto the heating plates. For example, <CIT> describes a process with a compressor to form the head. <CIT> also describes a process where a heated forming die is pressed onto the tampon blank in order to shape the introductory end. The issue in these processes is that the head-shaping step takes too much time because the quality of the heat-shaping depends on the temperature of the heating element and the duration of the heat-sealing step. More specifically, the quality is improved if heat-shaping is performed at lower temperature and for a longer duration, thus lowering production speed.

The invention aims to provide an apparatus and method which ensures a fast, efficient, reliable and cleaner shaping of the introductory end of a tampon.

The present invention provides an apparatus for shaping the introductory end of a tampon, comprising:.

According to the invention, the head-shaping station comprising an ultrasonic device, the ultrasonic device comprising at least one head-shaping sonotrode emitting ultrasonic vibrations at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably a frequency of <NUM>, the ultrasonic device comprises a first and a second head-shaping sonotrodes emitting ultrasonic vibrations at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably a frequency of <NUM>.

The ultrasonic device emitting ultrasonic vibrations enables to increase the number of hits to the tampon introductory end, when comparing to a conventional heating press, during a same amount of time. In other words, for the same amount of time, a ultrasonic device enables to get more hits to the tampon head in comparison to a convention heating press, thus the introductory end will be better shaped. Also, a conventional heating press requires <NUM> or <NUM> moulds to hit the tampon introductory end enough times to obtain a proper shaping of the head, whereas with an ultrasonic device, it is possible to reduce this number of moulds. This enable to improve the production yield, since the tampons can move quicker to a following stage, e.g. the wrapping step, where the tampon is covered by a wrapper.

According to an embodiment, the first and second head-shaping sonotrodes are aligned on an arcuate axis.

According to an embodiment, the head-shaping station comprises an actuation mechanism enabling the movement of the ultrasonic device closer or remoter to the support wheel and the tampon.

According to an embodiment, the apparatus comprises a pushing mechanism comprising a plate with at least one protruding peg to press against the trailing end of the tampon that is opposite to the introductory end.

According to an embodiment, the first and second head-shaping sonotrodes have different cross sectional profiles.

According to an embodiment, the head-shaping sonotrode has a cavity that is ogive shaped.

The invention also pertains to a method for shaping the introductory end of a tampon using the apparatus as described above, comprising the steps of:.

According to the invention, the shaping of the introductory end of the tampon is done with an ultrasonic device, the ultrasonic device comprising at least one head-shaping sonotrode emitting ultrasonic vibrations at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably a frequency of <NUM>, during a lapse of time which is comprised between <NUM>,<NUM> and <NUM>, preferably between <NUM>,<NUM> and <NUM>,<NUM>, the ultrasonic device comprises a first and a second head-shaping sonotrode emitting ultrasonic vibrations at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably a frequency of <NUM>, during a lapse of time which is comprised between <NUM>,<NUM> and <NUM>, preferably between <NUM>,<NUM> and <NUM>,<NUM>, the tampon being shaped by the first head-shaping sonotrode then subsequently by the second head-shaping sonotrode.

According to an embodiment, the shaping of the introductory end of the tampon further comprises the sub-steps:.

According to an embodiment, the method further comprises the sub-steps:.

All of these embodiments mentioned above can be taken individually or in combination.

Further embodiments are described below and in the claims.

The present invention concerns an improved apparatus for shaping the introductory end of a tampon, and a method using such apparatus, as well as the product manufactured by said method and apparatus.

"Comprise," "comprising," and "comprises" and "comprised of" as used herein are synonymous with "include", "including", "includes" or "contain", "containing", "contains" and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.

The term "emit ultrasonic vibrations" is equivalent to the term "apply ultrasonic vibrations to".

The terms "form" and "shape" are equivalent and means the spatial form or contour of an element and "shaping" means imparting a particular form or shape to an element, in particular the introductory end of a tampon.

The term "introductory end" equivalent to the term "head" means the end of the tampon that is designed to be inserted first in a body cavity. It corresponds to the end that is opposite of the end that presents the withdrawal string.

The term "trailing end" equivalent to the term "rear" means the end of the tampon that is designed to be inserted last in a body cavity. It corresponds to the end of that tampon that presents the withdrawal string.

The term "carrying pipe" means a housing with a tubular design that has a hollow inner space, or cavity, in order to receive tampon within said hollow inner space. In other words the carrying pipe corresponds to a hollow elongated cylinder.

The terms "sonotrode" and "head-shaping sonotrode" are equivalent.

The term "convex crown area" or "convex dome apex" designates a surface shape where each single point on the surface of the summit can be connected with each other point on the surface of the summit by means of lines running within the summit.

The term "nonwoven web material" means a sheet material having a structure of individual fibers or threads which are interlaid, but not in a regular manner such as occurs with knitting or weaving processes. Nonwoven fabrics or webs have been formed from many processes such as for example, melt blowing processes, spun bonding processes, and bonded carded web processes.

The term "thermoplastic" is meant to describe a material that softens when exposed to heat and which substantially returns to its original condition when cooled to room temperature.

The term "rayon" refers to a manufactured regenerated cellulose fiber, made from purified cellulose. It has a smooth, soft surface, and is therefore very suitable to be used in a tampon.

The term "concurrently" or "essentially concurrently" refers to the simultaneous or overlapping occurrence or execution of two or more events or steps.

A process for making a tampon comprises several steps. For example, the process comprises a bonding step where a first web material, for example an absorbent material such as rayon, viscose or cotton is bonded with a second web material, for example a thermoplastic film or a nonwoven web material. The process also comprises a winding and sealing step where the first and second web materials are winded and sealed together to form a tampon pre-blank. The tampon pre-blank is then compressed in a press. The compressed tampon is then transferred to the head-shaping apparatus according to the invention where the introductory end of the tampon is shaped. The tampon is then conveyed to a wrapping station where it is covered by a wrapper. Of course, the process can comprise additional steps such as the deposit of a withdrawal string and its knotting; the steps can be in this order or in another. The focus of the present invention pertains to a method for shaping the head, or introductory end, of a tampon and the apparatus to implement such method.

<FIG> illustrates a head shaping apparatus <NUM> according to the invention. The tampon pre-blank is transferred from a winding and sealing station (not illustrated) to a press <NUM>. The press <NUM> comprises a plurality of arms, for example <NUM>, <NUM>, <NUM> or <NUM> that press the tampon pre-blank into a compressed tampon with grooves on its outer surface. Each compressed tampon is then transferred to a support wheel <NUM> that comprises a plurality of carrying pipes <NUM>, or hollow tubes, each compressed tampon being placed in a carrying pipe <NUM>. Each carrying pipe <NUM> is hollow and extends in a longitudinal axis and has two open ends, one at each longitudinal end. Each compressed tampon is introduced within a carrying pipe <NUM>, namely within the hollow space defined by the cylindric walls of the carrying pipe <NUM>, through one open-end of the carrying pipe <NUM>. The support wheel <NUM> comprises actuation means to rotate: for example a motor or engine can rotate a shaft to make the support wheel <NUM> turn. The support wheel <NUM>, and therefore every carrying pipes <NUM> carried by the support wheel <NUM>, rotate in a clockwise or counter-clockwise direction, here in a clockwise direction, to guide the carrying pipe <NUM> towards the head-shaping station <NUM>.

<FIG> illustrates a close-up of the head-shaping station <NUM>, the support wheel <NUM> not being illustrated in this view for clarity reasons. The head-shaping station <NUM> comprises an ultrasonic device <NUM> and a pushing mechanism <NUM>. The ultrasonic device <NUM> comprises at least one vibration generator <NUM> (illustrated on <FIG>), for example and not limited to, a magnetostrictive or piezoelectric transducer. Said generator is attached to at least one tapering rod or probe usually made of metal, such as and not limited to titanium, aluminum or steel, that will be referenced herein as the head-shaping sonotrode <NUM>. Each head-shaping sonotrode <NUM> is submitted to the vibrations generated by a vibration generator <NUM> and said head-shaping sonotrode <NUM> then emits or applies this vibrational energy to the head of the compressed tampon <NUM>. The pushing mechanism <NUM> comprises a peg <NUM> that is narrower than the hollow carrying pipe <NUM>, said peg <NUM> being attached to a plate <NUM>. In other words, the peg <NUM>, corresponding here to a cylindrical finger that has a diameter that is smaller than the diameter of the carrying pipe <NUM>, in this manner is able to slide within the interior space of the carrying pipe <NUM> and press against the tampon <NUM>.

The plate <NUM> is attached to an actuating mechanism <NUM> (illustrated <FIG>) that can move the plate <NUM> back-and-forth. In other words, the actuating mechanism <NUM> is preferably a reciprocating mechanism imparting a back-and-forth linear motion. Such actuation mechanisms can comprise for example and not limited to, scotch yoke, slider-crank, piston or pneumatic engine, traction elevator geared or gearless, turbine, spring.

As illustrated here, the actuating mechanism <NUM> corresponds here to a crank mechanism combined with a rod. More specifically, the actuating mechanism <NUM> comprises an arm <NUM> that is fixed to the plate <NUM> through a reversible or permanent fixation. As illustrated here, the actuating mechanism <NUM> comprises a lever <NUM> which rotates in a back-and-forth motion F through the impulse of a shaft <NUM> that is rotated itself by a motor (not illustrated). The lever <NUM> is linked to the arm <NUM> so that said arm <NUM> also moves in a back-and-forth motion. The arm <NUM> being linked to the plate <NUM> also forces it to move in a back-and-forth reciprocate manner. The peg <NUM> being attached to the plate <NUM> also moves in the same back-and-forth movements as the plate <NUM>. The invention is not limited to this embodiment and other means of actuation can be considered as long as they induce a back-and-forth motion.

Preferably, the peg <NUM> and the plate <NUM> moves in a linear back and forth motion. In an embodiment, the plate <NUM> is carried by a sliding base <NUM> (as illustrated in <FIG>) that slides within a railing <NUM>, or rail tracks, (illustrated in <FIG> OR <FIG>) so as to restrain the movement of the plate <NUM> and peg to a linear reciprocating motion. The invention is not limited to this embodiment, for example the plate <NUM> can be attached to a sliding base comprising at least one peg that slides within a cam track.

The amplitude of the movement of the plate and peg is limited by the rotation of the lever <NUM>, the length of the arm <NUM>. In addition or alternatively, the railing <NUM> can comprise stop ends to define a limit to the railing or cam track and restrict the movement of the plate <NUM> and pegs <NUM>.

As illustrated in <FIG>, a plurality of pegs <NUM>, here two, are carried by the plate <NUM>. Of course, the invention is not limited to this embodiment and the number of pegs carried by a plate <NUM> can vary from <NUM> to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or more pegs <NUM>. Each peg <NUM> can form a continuity of matter with the plate <NUM> or be reversibly attached to the plate <NUM> as illustrated here, this way it is possible to adapt the number of pegs in accordance with the number of functional head-shaping sonotrodes <NUM>. Each peg <NUM> corresponds to a right or straight cylinder that extends in a longitudinal direction, namely, each peg <NUM> extends in the same direction as the railing <NUM> or the reciprocating direction imparted by the actuating mechanism <NUM>. Each peg <NUM> has one end fixed or forming continuity of matter with the plate <NUM> and the opposed end that is either flat, chamfered, convex or concave. The pegs <NUM> can be identical to one another or have different shapes and/or dimensions.

As explained above, the diameter of the peg is smaller than the diameter of the hollow carrying pipe <NUM> so that when the pegs <NUM> are in motion thanks to the actuating mechanism <NUM>, they slide within the hollow space of the carrying pipe <NUM>.

As explained above, the number of pegs <NUM> on the plate <NUM> corresponds to the number of functional head-shaping sonotrodes <NUM> present at the head-shaping station <NUM>. In the example illustrated in <FIG>, the head-shaping station <NUM>, specifically the ultrasonic device <NUM>, comprises two head-shaping sonotrodes <NUM>. Of course, the invention is not limited to said number of sonotrodes and the head-shaping station <NUM> can comprise <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or more sonotrodes. Of course, the head-shaping process lasts for a certain amount of time. Not shaping enough the head <NUM>, or introductory end, of a tampon <NUM> can lead to a product being unfinished and/or uncomfortable to insert, while having too many head-shaping steps causes a loss of time and reduces the production yield. It is a balance between a proper introductory end shape and manufacturing yield. By using a head-shaping station <NUM> comprising an ultrasonic device <NUM>, the inventors have discovered a surprising effect whereby the sonotrode is able to apply more hits to the compressed tampon pre-blanks thus enabling a better head shape or design when applying less time or the same amount of time as for a conventional heated hammer. This improvement enables to reduce the number of moulds where five or six moulds are conventionally used for heat-plate hammers. With this improved apparatus <NUM>, it is possible to obtain a better result with two ultrasonic moulds or sonotrodes <NUM>. Secondly, the usage of ultrasonic bonding has also the significant benefit that it does not provoke any undesired melting of the film which can occur when using heat-plate hammers because of radiant heating phenomena, resulting in a cleaner process.

As recited hereinabove, each compressed tampon pre-blank is transferred from the press <NUM> to a hollow carrying pipe <NUM>, specifically within the interior space of the carrying pipe <NUM>. The support wheel <NUM> then rotates in a clockwise direction so that the compressed tampon pre-blank reaches the head-shaping station <NUM>. At that point, the peg <NUM> slides within the hollow carrying pipe and pushes the compressed tampon <NUM> against the head-shaping sonotrode <NUM>. Each head-shaping sonotrode <NUM> applies ultrasonic vibrations at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably <NUM>, to the introductory end <NUM> of the tampon <NUM>. The introductory end <NUM> of the tampon <NUM> is thereby shaped in a dome-like configuration in order to have a shape that is more comfortable to insert in a body cavity.

<FIG> illustrates a close-up of an embodiment of the ultrasonic device <NUM> according to the invention. The ultrasonic device <NUM> comprises here two head-shaping sonotrodes <NUM> and a pusher <NUM>. The two sonotrodes <NUM> and the pusher <NUM> are aligned in this order along an arcuate axis, following the same direction and radius as the support wheel <NUM>, and the angle between the sonotrodes <NUM> or the sonotrode in the middle <NUM> and the pusher <NUM> corresponds to the same angle between two carrying pipes <NUM>. The angle between two carrying pipes <NUM> is comprised between <NUM>° and <NUM>°, for example between <NUM>° and <NUM>°, for example is about <NUM>°. The first sonotrode 116a corresponds to the pre-shaping sonotrode whereas the second sonotrode 116b corresponds to the final shaping sonotrode.

<FIG> illustrates a cross-section of a sonotrode <NUM> in a side or top view. The head-shaping sonotrode <NUM> corresponds to a metal rod with an excavation at one end thus defining two branches <NUM> and a cavity <NUM> in between the two branches in a cross-sectional profile. Each sonotrode <NUM> has a cavity <NUM> that is ogive shaped with a diameter d and a length L. The diameter d of the cavity <NUM> is comprised between <NUM> and <NUM>, preferably between <NUM> and <NUM>, more preferably the diameter d is <NUM>. The diameter d of the cavity <NUM> corresponds substantially to the diameter of the tampon <NUM>. The length L of the cavity <NUM> is comprised between <NUM> and <NUM>, preferably between <NUM> and <NUM>, more preferably the length L is <NUM>. Here the length L of the cavity <NUM> is smaller than the diameter d of the cavity <NUM>. Such dimensions are particularly suited to define a well-shaped introductory end <NUM> for the tampon <NUM>. The extremities of the branches <NUM> can present a chamfer <NUM>, or bevel, on the inner side, i.e. the side adjacent to the cavity <NUM>, in order to have more clearance when the introductory end <NUM> of the tampon is introduced within the cavity <NUM> of the sonotrode <NUM>. The cavity <NUM> can have other profile, for example it can have a half, or truncated, squircle profile.

The tip, or extremity, <NUM> of the ogive-shaped cavity <NUM> can be round shaped so that the tampon can have a dome-shaped meaning a convex dome apex or convex crown area. The tip <NUM> of the cavity <NUM> corresponds to the central part of the cavity <NUM>, or the point where the two branches <NUM> start to branch out as illustrated in <FIG>. For example, the cavity <NUM> can be in the form of a hemispherical dome so as to shape a tampon with an introductory end <NUM> with a hemispherical dome profile. The tip <NUM> of the ogive-shape cavity <NUM> can have a flat portion at its end so the tampon displays a truncated domed-shape introductory end. The tip <NUM> of the ogive-shape cavity <NUM> can also be convex so as to form a tampon <NUM> with a concave dome apex at its introductory end <NUM> as illustrated in <FIG>. To sum up, the cavity <NUM> can have different nose cone profile for example hemispherical, elliptical, tangent, spherical blunted tangent, etc. depending on the desired final shape.

The first and second sonotrode 116a, 116b can have the same profile, or shape, and/or dimensions, to ensure that the introductory end <NUM> of the tampon <NUM> is identical.

Alternatively, the two sonotrodes <NUM> can have different profiles, or shapes, and/or dimensions so that the second sonotrode 116b can make a fine tuning of the introductory end. For example, the cavity of the second sonotrode 116b can have the same diameter d as the first sonotrode 116a but a smaller length L than the cavity of the first sonotrode 116a in order to shape only a part of the introductory end <NUM>.

In the embodiment where the first and second sonotrode 116a,116b have different dimensions, the pegs <NUM> preferably have different dimensions so that a peg <NUM> is adapted to the specific length of the corresponding sonotrode <NUM>. For example, if the second sonotrode 116b has a smaller length L than the first sonotrode 116a, than the first peg 118a will have a longer length than the second peg 118b to compensate this length gap. Alternatively, the first and second pegs 118a,118b can have the same length and the second sonotrode 116b can be slightly shifted towards the support wheel <NUM> and the carrying pipe <NUM> to compensate the length difference, or in other words, the second sonotrode 116b is slightly shifted in a direction that is orthogonal to the axis on which the sonotrodes are aligned.

According to an embodiment not illustrated, ribs can also be placed within the cavity in order to form additional grooves <NUM> on the tampon head.

Preferably, the ultrasonic device <NUM> also moves in a linear back-and-forth motion. In an embodiment, the ultrasonic device <NUM> is carried by a sliding base <NUM> (as illustrated in <FIG>) that slides within a railing, or rail tracks, so to restrain the movement of the ultrasonic device <NUM> to a linear reciprocating motion. Preferably, the sliding base <NUM> slides within the same railing as the sliding base <NUM> of the actuating mechanism <NUM>. As illustrated in <FIG>, the railing <NUM> enables the sliding of both the sliding base <NUM> carrying the plate <NUM> and pegs <NUM> and the sliding base <NUM> carrying the ultrasonic device <NUM>. The invention is not limited to this embodiment, for example the ultrasonic device <NUM> can be attached to a sliding base comprising at least one peg that slides within a cam track. The ultrasonic device <NUM> can be carried directly by the sliding base <NUM>, or it can be carried by a plate <NUM> that is fixed to the sliding base <NUM> as illustrated in <FIG>.

The plate <NUM> is attached to an actuation mechanism <NUM> (illustrated in <FIG>) that can move the plate <NUM> back-and-forth. The actuation mechanism <NUM> is as described above, preferably a reciprocating mechanism inducing a back-and-forth linear motion. The actuation mechanism <NUM> for the ultrasonic device <NUM>, as the actuating mechanism <NUM> of the plate <NUM> and pegs <NUM>, comprises a lever <NUM> which rotates in a back-and-forth motion through the impulse of a shaft that is rotated itself by a motor (not illustrated). The lever <NUM> is linked to an arm <NUM> so that said arm <NUM> also moves in a back-and-forth motion. The arm <NUM> being linked to the plate <NUM> also forces it to move in a back-and-forth reciprocate manner. The ultrasonic device <NUM> being attached to the plate <NUM> also moves in the same back-and-forth movements as the plate <NUM>. The invention is not limited to this embodiment and other means of actuation can be considered as long as they induce a back-and-forth motion.

A method for shaping the introductory end of a tampon <NUM> according to the invention comprises the following steps as illustrated in <FIG>. Each tampon <NUM>, after being compressed in the press <NUM>, is placed inside a carrying pipe <NUM>, preferably with a portion of the tampon <NUM> sticking out of the carrying pipe <NUM>. The support wheel <NUM> rotates and the carrying pipe <NUM> and tampon <NUM> are then conveyed to the head-shaping station <NUM>, more specifically up to the first sonotrode 116a location as schematically illustrated in <FIG>. The introductory end <NUM> of the tampon <NUM> is then shaped at this location. More specifically, as schematically illustrated in <FIG> the first sonotrode 116a and the first peg 118a slide forth, preferably simultaneously, towards the support wheel <NUM>, the carrying pipe <NUM> and the tampon <NUM>. The first sonotrode 116a slides to abut against the tampon's head <NUM> and the first peg 118a slides to abut against the trailing end <NUM> of the tampon <NUM> and counters the force applied by the first sonotrode 116a. The first sonotrodes 116a then emits ultrasonic vibrations at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably <NUM>, during a lapse of time which is comprised between <NUM>,<NUM> and <NUM>, preferably between <NUM>,<NUM> and <NUM>,<NUM>, for example <NUM>,<NUM>. The first sonotrode 116a and then the first peg 118a slide back, preferably concurrently, away for the support wheel <NUM>, the carrying pipe <NUM> and the head-shaped tampon <NUM> as illustrated in <FIG>. The support wheel <NUM> then rotates again and coveys the carrying pipe <NUM> and the shaped tampon <NUM> towards the second sonotrode 116b. According to this embodiment, the pushing mechanisms <NUM>, i.e. peg <NUM>, and the ultrasonic device <NUM>, i.e. sonotrode <NUM>, preferably simultaneously slide back-and-forth in opposite linear direction; this enables to improve the yield time.

The invention is not limited to the previous embodiment. For example, according to another embodiment which is not illustrated, each compressed tampon arranged in a carrying pipe <NUM>, is transported up to the first sonotrode 116a location. The first peg 118a is moved by the actuating mechanism <NUM> and slides forth within the carrying pipe <NUM>. The first peg 118a abuts against the compressed tampon <NUM>, specifically the trailing end <NUM> of the tampon <NUM>, and pushes said tampon <NUM> up against the first sonotrode 116a specifically within the cavity <NUM> of the sonotrode <NUM> which stays stationary at this point. The first sonotrode 116a applies ultrasonic vibrations to the tampon introductory end <NUM> at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably <NUM>, during a lapse of time which is comprised between <NUM>,<NUM> and <NUM>, preferably between <NUM>,<NUM> and <NUM>,<NUM>, for example <NUM>,<NUM>. The peg <NUM> and the sonotrode <NUM> then slide concurrently towards the plate <NUM> so that the sonotrode <NUM> can push the tampon <NUM> back to its previous position in the carrying pipe <NUM>. In other words, the sonotrode <NUM> slides forth towards the support wheel <NUM> whereas the peg <NUM> slides back away from the support wheel <NUM>. The sonotrode <NUM> then slides backwards to its stationary position. This embodiment enables that the tampon <NUM> does not need to have a protruding portion sticking out from the carrying pipe <NUM> before reaching the head-shaping station <NUM> thus limiting contamination risks.

After the tampon introductory end has been shaped by the first sonotrode 116a, the support wheel <NUM> rotates and the carrying pipe <NUM> and tampon <NUM> are transferred to the second sonotrode 116b location. The tampon <NUM> can undergo the same process steps as described above for both sonotrodes. Alternatively, the tampon <NUM> can undergo the process steps described in the first illustrated embodiment for the first sonotrode and the alternative process steps for the second sonotrode or vice versa.

After the tampon introductory end has been shaped by the second sonotrode 116b, the support wheel <NUM> rotates and the carrying pipe <NUM> and head-shaped tampon <NUM> are transferred to the pusher <NUM> location. As illustrated in <FIG>, the pusher <NUM> corresponds to a cylinder or peg with a washer <NUM> at one end and the other end is fixed to, or forms continuity of matter with, a connecting rod <NUM> that is linked to the plate <NUM> and incidentally the sliding base <NUM> so as to move simultaneously in the same back and forth motion as the sonotrodes <NUM>. The end with a washer <NUM> has a portion <NUM> of the cylinder or peg that protrudes from the washer <NUM>. The diameter of the washer <NUM> is superior to the diameter of the carrying pipe <NUM> and the diameter of the pusher <NUM> and in particular of said portion <NUM> is substantially equal to the diameter of the tampon, thus inferior to the diameter of the carrying pipe <NUM>. The pusher <NUM> slides forth and pushes back the head-shaped tampon <NUM> within the carrying pipe <NUM> up to the point where the washer <NUM> abuts against the carrying pipe <NUM> as illustrated in <FIG>. The end with the portion <NUM> can also have a concave profile to push the tampon <NUM> without deforming the introductory end <NUM> as illustrated in <FIG>. The pusher slides back afterwards according to the movement induced by the sliding base <NUM> and the actuation mechanism <NUM>. This step enables the tampon <NUM> to be rightfully positioned within the carrying pipe <NUM> with no portion protruding out of the carrying pipe <NUM> thus limiting contamination risks during the transfer of the tampon <NUM> to the wrapping station.

The support wheel <NUM> rotates and the carrying pipe <NUM> is transferred to a transfer device <NUM> location. The transfer device <NUM> corresponds to a device that can push or pull the tampon <NUM> out of the carrying pipe <NUM> onwards to the wrapping station where the tampon <NUM> is covered by a wrapper. In other words, the process comprises a step where the tampon <NUM> is ejected from the carrying pipe <NUM>.

<FIG> illustrates a tampon <NUM> after having been shaped by the first and second sonotrodes 116a, 116b. The tampon <NUM> comprises a cylindrical body <NUM> extending in a longitudinal direction. Incidentally the carrying pipe <NUM> is a hollow cylindrical body extending in the same longitudinal direction and that has a larger diameter than the tampon <NUM> so that said tampon <NUM> can be placed within the inner space of the carrying pipe <NUM>. On its outer surface, the tampon <NUM> can comprise grooves <NUM> to improve fluid absorption. As illustrated in <FIG>, the tampon <NUM> comprises a withdrawal string <NUM> on its rear or trailing end <NUM>. The trailing end <NUM> corresponds to the longitudinal end of tampon that is opposite to the longitudinal end that is shaped by the sonotrodes <NUM>. The head, or introductory end, <NUM> shaped by the sonotrodes <NUM> has a dome like configuration. It can present a concave apex area <NUM>, if the tip <NUM> of the ogive-shape cavity <NUM> is convex. Alternatively, the head <NUM> of the tampon can have a convex dome apex or convex crown area for example in the form or shape of a hemispherical dome. The introductory end <NUM> can comprise one or more additional grooves <NUM> should one or more ribs be arranged within the sonotrode cavity <NUM>.

Claim 1:
Apparatus (<NUM>) for shaping the introductory end (<NUM>) of a tampon (<NUM>), comprising:
- a carrying pipe (<NUM>) for holding the tampon (<NUM>);
- a support wheel (<NUM>) that carries a plurality of carrying pipes (<NUM>), the support wheel (<NUM>) comprising conveying means to transport each carrying pipe (<NUM>); and
- a head-shaping station (<NUM>) for shaping the introductory end (<NUM>) of the tampon (<NUM>);
the head-shaping station (<NUM>) comprising an ultrasonic device (<NUM>), the ultrasonic device (<NUM>) comprising at least one head-shaping sonotrode (<NUM>) emitting ultrasonic vibrations at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably <NUM>,
characterized in that the ultrasonic device (<NUM>) comprises a first and a second head-shaping sonotrode (116a, 116b) emitting ultrasonic vibrations at a frequency between <NUM> and <NUM>, preferably between <NUM> and <NUM>, preferably <NUM>.