Note: Descriptions are shown in the official language in which they were submitted.
105Z5~Z
The prQsent invention relates to an absorbent mate-
rial and the method~ Or making the same. While various applica-
tions ror such absorbent mat~rial are contemplated, the pre~ent
invention rinds speciric application for use in catamenial de-
vices such as tampons.
Tampons en~oy a wide acceptanoe and various ¢ata-
menial devices have been developed, employlng various mate-
rial compositions which must provide a relatively high degree
o~ absorbenoy in a product which i8 rslatively oompaot and
economical to manu~acture.
Aside rrom its absorbent characteristics, the mate-
rial employed must be comrortable 90 as to allow read~r inser-
tion into the vaginal canal; have a strength sui`~icient to
retain its ~ntegrlty ln use; and ~urther have the ability to
expand,onoe sub~ec~ed to ehe moisture in the vaginal oanal 90
as to oon~orm to the spaoe between the walls Or the canal to
.. ..
prevent lealcage Or the menstrual disoharge and still allow ror
easy withdrawal.
The materials employed must also be adapted to be
l 20 made economically both with respeot to material cost and manu^
li racture processes.
Present catamenial devices generally employ ~ibrous
materlals such a9 cellulosic struotures, prinolpally rayon,
cotton, paper or mixtures or blends thereo~ depending prinoi-
pally upon t~e absorptive oapaoities Or the bulk o~ the mate-
rlals to inorease absorbenoy. Aside ~rom varying the type o~
raw materials employed, by and large developments to increase
and/or enhance absorptive oapacity has been dealt with by either
adding to the bulk o~ the material and/or the oompression Or the
30 materials 90 as to add quantitatively to the mass Or absorbent
material within a given volume.
A~ As hereinarter more speoirioally described, a method
has been ~ound to increase the absorbency levels o~ more econo-
lOSA~50Z
mical, lescer absorbent raw materials so as to enable the substitution of
such materials, in, for example, a catamenital device, with the finished
product having an absorptive capacity which is at least at a parity with a
product of equal weight heretofore constructed of more expensive, greater
absorbent raw materials.
According to the present invention there is provided a tampon
comprising at least two juxtaposed layers of absorbent material, wherein a
first layer is a sheet of cellulose crepe wadding having a plurality of
openings extending therethrough, and a second layer is a fibrous mat of rayon
filaments, wherein a plurality of the rayon filaments extend through said
openings in said sheet of crepe cellulose and stand in tufts or loops proud
of the surface of said sheet opposite that surface in contact with said
second layer, wherein said layers together form an absorbent composite, and
wherein said absorbent composite is oriented within the tampon with the
filament receiving openings directed generally outwardly to provide an
extended absorbing surface area which also provides a wicking action to
conduct fluid from the surface through the holes into the layers of the
laminate.
It has been determined that particularly desirable results are
2Q obtained if the two layers are dissimilar and where both layers are
absoxbent materials. Further, o~e of the layers preferably is adapted to
act as a matrix with the filaments of the other of the layers extending
through openings in the matrix layer.
For example, a tampon having absorbent material weighing 2.2 grams,
fifty per cent (50%) of which is rayon and fifty per cent (50%) of which is
cellulose crepe wadding normally has an absorbency equal to only eighty per
cent (80%) of an identically constructed, more expensive all rayon tampo~
having absorbent material weighing 2.2 grams.
If however, the same rayon and cellulose crepe wadding constituents
3Q are modified in accordance with the present
l~szsa2
invention to provide openings through the cellulose crepe wadd-
ing, and a plurality of the filaments of the rayon are trans-
ferred through such openings the tampon will have an absorbency
level equal to the more expensive all rayon tampon.
The absorptive composite of the present invention is
preferably formed by juxtaposing in substantially superimposed
relationship, two constituent materials; at least one of such
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lOSZSO~
materials being of an ab~orptive substance, and at least one of
such materials including rilaments; forming openings through at
l~ast one of such materials, and transferring ~ila~ents from
such filament bearing material through the other Or such mate-
rials.
Pre~erably the formation of the openings and the fila-
ment transference steps are accomplished in a single operation
. ,i
~,s; by the use Or barbed needles, such as the type commonly referred
to as "felting needles" with a least portion Or the barbs oriented
along the shank of the needle in the direction of the desired
filament trsnsrerence.
In a tampon it is preferably that the transference Or
filaments be Or a degree such that the num~er Or rilaments on
either face of the matrix layer be substantially equal.
It is believed that the increase in absorbency Or the
material o~ the present invention is due to alteration in the in-
terstitial spacing effected during transrqrence, the in-
crease Or the surrace area efrected in the creation of the open-
ings, and/or the wicking or capillarity between layers along the
trsnsferred through rilaments. The transrerred through rilaments
act not only to maintain the integrity Or the united constituent
materials but rurther serve to maintain the integrity Or the
openings through the layers. This latter ~eature has special
pertinency in the use Or the absorbent material in catamenial
devices where the forming machinery generally exerts a crimping
pressure on the material being processed to ~hape and "set'~ the
tampan.
Although such novel feature or features believed to be
characteristic of the invention are pointed out in the claims,
the invention and the manner in which it may be carriad out may
be further under~tood by reference to the description rollowing
-1 and the accompanying drawings.
.~ ~.
Fig, 1 is a top elevational view of an absorbent mate-
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lOSZ50Z
ria~ o~ the present invention, with a corner o~ one o~ the layers
folded back to indicate the manner in whi¢h the ~ilaments o~ one
`~ layer are trans~erred through the openines provided in the other
layer.
Fig. 2 i9 a cross sectional view taken along lines 2-2
o~ Fig. 1 with dimensions exaggerated ~or clarity.
Fig. 3 is a cross sectional view, also exaggerated ror
clarity, of another embodiment Or the present invention.
Fig. 4 is a cross se¢tional view, similarl~ exaggerated
~or clarity, of an alternate embodiment o~ an absorbent material
the present invention.
Fig. 5 i9 a s¢hematic illustration of an apparatus
~or constructing an absorbent material in a¢cordance with a
method o~ the present invention.
F~ss. 6 a-c are side elevations illustrating the sequen-
tial rilament trans~erence o~ the present invention; Fig.6a illus-
tratin6 superimposed layers o~ constituent material be~ore the
entry Or the transrer needle; Fig 6b illustrating a trans~er
needle as it transrers ~ilaments; and Fig.6c illustrating the
trans~er needle as it is withdrawn rrom the united constituent
layers with the transrerred rilaments extending through the open-
ings.
Figs. 7-9 are side elevational views Or various trans-
~erring needles whi¢h may be employed.
Fig. 10 is a sectionalized perspe¢tive Or a portion Or
a tampon employing absorbent material Or the present invention.
Fig. 11 is a side elevation illustrating the absorbent
material Or the present invention rormed as a tampon and disposed
within a tampon insertion devioe, partially cut-away.
Re~erring now to the Fi6ur~s in greater detail, where
li~e rererence numbers denote like parts in the various Figures.
Illustrated in Figs. 1 and 2 i9 one rorm Or an absorbent
composite 1 Or the present invention. While various materials
~4~
` 105;~SOZ
may be employed, the particular composite shown comprises two
dissimilar constituents 2,3 both o~ which are absorbent, and
at least one Or which (2) contains relatively long ~ilaments.
For example, one or the con~tituents 2 is a ribrous substawe,
~uch as rayon and its companion constituent 3 is an absorbent
paper such as cellulose crepe wadding.
- As shown in Figs. 1 and 2 the absorbent composlte is
provided with a plurality o~ openings 4 extending through the
cellulose orepe wadding layer 3 through which the rilaments 2'
10 Or the rayon ribrous material 2 pass, suoh that rilaments 2~ and
2" extend on opposite races Or the crepe wadding layer 3.
For clarity, the constituents 2,3 may be rererred to
as "layers" although as illustrated in Figs. 1 and 2, the trans-
rerence Or the riber ~ilaments 2' Or the ~ibrous material 2 throu~;h
the companion layer 3 has been accomplished in a manne~ 90 as to
substantially equalize the number Or transrerred rilaments 2'
and non-transrerred rilaments 2" at the opposed races Or the com-
panion layer 3.
In Fig. 3 the absorbent composite 5 illustrated also
20 includes dissimilar constituents with a ribrous layer 6 and a
oompanion matrix layer 7. However, a lesser portion 8 o~ the
riiaments oi~ the ~ibrous layer 6 are transferred through the
openings 9 in the companion matrix layer 7 90 as to be exposed
on the outer race Or the companion layer 7.
.~. - .
Whereas Pigs. 1-3 illustrate embodimentq including
two starting "layers", various other combinations Or multi-
lsyers of msterial are possible. In Fig. 4 ror example there
is illustrated an absorbent composi;te 10 including an inner layer
o~ ~ibrous material 11 and a pair Or outer matrix layers 14. A
30 portion Or the ~ilaments 12 of the inner layer 11 have been trans-
ferred through openings 13 in both outer ~uperimposed layers 14.
It is to be appreciated that the "layers" o~ the absor-
bent composite illustrated in Figs. 1-4 are not necessarily as
-$-
105ZSOZ
clearly de~ined as illustrated. In the manu~acture of such mat-
erial the rilament transrerenoe is such that while the constituent
materials rétain their respective identitie~ a selective union Or
the materials results visually integrating the constituents.
The amo~nt Or openings and rilaments trsnsrerred per
unit, can vqr~ depending upon the degreq Or increased absorbency
desired ranging rrom a small number Or openings to that degree of
openings which would destroy the matrix layer. Since it is de-
sired to have at least some rilaments passing through each Or the
openings to maintain the integrity Or the openings, a particularly
ravorable union would be a uniting such as illustrated in Fig. Z
where there is a substantial equalization Or rilaments on oppo-
site races Or the matrix layer. There i9 thus provided substan-
tially equalized wicking on both races Or the matri~ with rila-
ments extending through all Or the openings.-
Re~erring to Fig. ~ there is illustrated an apparatus
~or processlng an absorbent composite in accordance with the pre-
sent invention.
A web Or ~lbrous material 15 is red such as rrom à~pool
16 to a needle punching machine 17. A second web Or material 18
is,,also red, such as rrom a spool 19 90 as to lie in superimposed
r01ationship with the ribrous material 1~ when the two webs 15,
18 are positioned at the work station area 20 Or the needle punch-
ing machine 17.
The needle punching machine 17 depicted i~ but a schem-
atic representation encompassing in a broad sense the basic o~era-
tion Or needle punch equipment, it being understood that various
,,apparatus are available to per~orm the riber rilament transrer-
enee and hole punohing runctions requisite in rorming the absor-
bent ~aterial or''the present invention. As illustrated~ thc needlo
punching machine 17 includes a recipro¢ally driven piston 21
adapted to driYe a needle beam 22 carrying a plurality ar verti-
cally oriented barbed needles 23 90 a9 to vertically actuate
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lOSZ502
the needles 23 to vertically reoiprooate them into needle re-
ceptaoles 24 in the bed 25. A transference e~ the ri1~ments
and ~ union Or the webs 15, lB also ocours and the 9e processed
resultant absorbent material 27 is taken up, such as by take-up
spool ~8.
As is more clearly illustrated in Figs. 6 a-c, the
needles 23 pass through the webs 15, 18 e~recting openings. The
barbs 26 ef~ect 8 fiber ~ilament transrerence ~rom the fibrous
web 15 throu~h the formed openings in the second web 18.
The orientation o~ the barbs and the stroke Or the
needles must be such 8S to er~ect a transference~ that i9 the
barbs must pass completely through the webs. The sequential steps
are illustrated in Figs, 6a through 6c wherein the barbs 26 en-
~age a portion oi~ the ~ilaments on the web 15. The point Or the
needl~ 23 punctures the web 18 and the rilaments engaged by the
barbs 26 are trans~erred through the openings 90 made. The needle
23 i~ then retracted with the rilaments disengaged rrom the
barbs, such rilaments remaining within the openings and extend-
ing through the web 18.
Varioue needle con~igurations are possible. In Fig. 7
for example the needle 29 is constructed having barbs 30 dis-
posed along its shank 31 such that the barbs 30 would engage
rilaments and transrer them in the direction o~ the arrow A.
Such a needle conriguration would be employed where the shank
31 would first pass through the ribrous material and then the
transreree web such as is shown in Fig. 5 and Fi~9. 6 a-c.
Were the web superimposition Or Fig. 5 reversed, such
as by having the transfered web rirst sub~ected to the needle
shank, a needle 32 such as illustrated in Fig. 8 would be suit-
able. The barbs 33 on the needle 32 are aligned 90 as to engage
a portion of the fiber filaments on the ~ibrous web and draw such
rilaments through the needle made openings in the transreree web.
Or, in the alternative in lieu o~ the unidirectional ~iber ~ila-
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.
` lOSZSOZ
mènts transrerence c~ Fig. 5, transrerence between webs c~n be
accomplished rrom both above and below the webs employing various
oombinations Or needles 29,32 and 34 illustrated in Figs. 7, 8
and 9 respectively.
Further this multi-station, above and below technique
may be employed, where multiple webs are employed, such as the
three (3) webs which initiate the absorbent material 10 shown in
Fig. 4.
An alternative method Or constru¢ting a multi-layered
composite such as the composite Or Fig. 4 may be aocomplished by
use Or needles, such as illustrated by the needle 34 Or Fig. 9.
The needle 34 Or Fig. 9 includes along its shank 31, both barbs
36 ~or transrerence in one direction and barbs 37 for transrer-
ence in the opposite direction. The downward stroke Or th~ needle
through the multiple webs would transrer rilaments in the direc-
tion Or the stroke through the bottom web. The reciprocal re-
tracting motion Or the needle would transrer rilaments rrom the
central web Or ~ibrous material through the upper web.
Filament transrerence including the provision Or opqn-
- ings has resulted in increased absorbency and this has been round
to be~ Or particular value in the construction Or tampons. As
illustrated in Fig. 10, a typical tampon structure Or the present
invention is shown.
The tampon illustrated may be constructed in a variety
Or ways using various manuracturing techniques. For example, a
multiphase linear rlow machine such as depicted in United States
Patent No, 3,4~5,390 to Mooney mRy be ~mployed.
The tampon 43 shown includes two (2) layers Or super-
imposed absorbent material 38 constructed in accordance with the
present invention. A gauze layer 44 ror strong securement is
positioned between the two (2) absorbent material layer~ 38 and
! a withdrawal string 39 extends through the layers 38,44.
While a gsuze layer 44 has been illustrated such gauze
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~05;~50Z
layer 44 may be dispen~ed with in ~mbodiments where the matrix
layer of the ab90rbent material 38 i9 0~ a su~ricient strength to
maintain the string 39 securely e~en a~ter the absorbent material
38 bas been sub~ected to moisture.
Illustrated in Fig. 11 is the tampon of Fig, 10 ioaded
into a telescoping tube inserter device 40 such as those presently
available in the art. It might ~urther be noted that as ~ormed
the openings 41 and ~ibers 42 extend transversely with respect
to the body portion of the tampon thus ~acilitating not only the
10 - absorption Or menstrual fluid, but ~urther present a network o~
openings f`or the menstrual discharge.
As will be seen ~rom the examples which ~ollow, com-
bined absorbent and non-absorbent materials can be employed in
the rormation o~ an acceptable starting material ror use as a
tampon and the non-absorbent constituents may be chosen ~or both
strength and selective functionality. Further, enhancament Or
absorbent characteristics is also provided in an all rayon com-
bination.
The following test results are believed indicative Or
20 the enhanced properties Or an absorbent material constructed in
accordance with the present invention.
So as to provide more definitive results all Or the
f'ollowing samples were rormed into tampons and absorbency levels
were determined in such condition. Each Or the tampons tested
had a weight Or approximately 2.4 grams with 2.2 grams being Or
absorbent material and the remaining .2 grams including the inter-
mediate gauze layer. It is Or note that in the making Or the
tampons pressure is applied to the material sur~ace to close some
Or the openings in those samples (such as samples V and VI in~ra,
30 where the shortness o~ the rilaments Or the eellulose crepe wadd-
ing prevented such rilaments rrom maintaining the integrity Or the
openings, thus accounting in some degree ~'or the relatively minor
increment in absorbency levels.
_9_
` ~)5Z51)Z
Absorbency levels were tested employing the Syngyna
Method. A summary of the Syngyna Method may be found in a paper
entitled "A Comparison of the Absorptive Efficiency Or the Comm-
. ..
ercial Catamenial Tampons" w~itten by Professor G,W. Rapp andpublished in June 1958 (Dept. of Research, Loyola Univ., Chicago,
Ill.).
The Syngyna Method basically consists of applying to
a properly positioned tampon an adaptation pressure o~ physio-
logica] magnitude and then allowing a rluid o~ proper consist-
ency to flow at its tip at a controlled rate. The test i9 con-
cluded when the first drop of ~luid begins to fall from the open
end Or the "Syngyna" regardless of whether the tampon seems sat-
~rated or not.
Using as a control an all rayon tampon tweighing 2.4
grams) which has a Syngyna absorbency level in grams o~ 11.2,
the following tests are exemplary Or the present invention. The
examples are given by way Or illustration and are not intended
to limit the invention.
MATERIAL TRANSFERENCE
I. EMPLOYED METHOD RESULTS
50% rayon 3 Barbed needles, Syngyna absorbency
denier, 1 9/16 triangular shank, of 11.2 grams
fiber length 15 gauge (.072
-50% cellulose inches) diameter
crepe wadding - 800 needle holes
10 lb. per 3000 per square inch
sq. feet (10 9 barbs per
plies) needle
I MATERIAL TRANSFERENCE
3o II. EMPLOYED METHOD RESULTS
-50% rayon 3 NONE Syngyna absorbency
denier, 1 9/16 of 9.0 grams
~iber length
-50% cellulo9e
crepe wadding
10 lb. wgt. per
3000 sq. feet
(10 plies)
The 50~ rayon, 50% cellulose crepe wadding sample e~-
hibited progressively enhanced absorbency level9 ~9 the needle
transferring operation progressed as can be s~en from thechart
-10-
~052SOZ
below:
SYNGYNA ABSO~RBENCIES IN GRAMS
NO PUNCHES100 PUNCHES 400 PUNCHES 800 PUNCHES CONTROL
9.0 9.9 10.4 11.2 11.2
A further des1rable result o~ the above two ~amples was
disoovered. A single layer o~ oellulose crepe wadding (10 lb.
wgt, per 3000 sq. feet - 10 ply) alone was needle punched by the
9ame needle punching equipment Or sample I. Such sampling started
to loo~e its integrity at approximately ôOO punches per square
inch whereas the same material maintained its integrity when sub-
~ected to the same amount Or needle punches as part o~ the rayon-
cellulose cr~pe wadding union Or sample I.
As can be noted ~rom sample I above a more economical
material, that is cellulose crepe wadding has been substituted
ror a substantial portion Or the rayon in the tampon. Normally,
as shown in sample II this substitution would e~eot a 20% 1099
in absorbency. However, as illustrated the material of sample I
was brought to the level o~ absorbency o~ an all rayon tampon Or
equal weight.
M~TERIAL TRANSE13RENCE
III. EMPLOYED METHOD RESULTS
-40% rayon 3 Barbed needles~, Syngyna absorbency
denier, 1 9/16 triangular shank Or 10.40 grams
fiber length 15 gauge (-072
-60% cellulose inches diameter)
crepe wadding 800 needle holes
10 lb. wgt. per per square inch
3000 sq. ~eet 9 barbs per needle.
(10 plies)
MATERIAL TRANSFERENCE
IV. EMPLOYED METHOD RESULTS
25~ rayon 3 Barbed needles, Syngyna absorbency
denier, 1 9/16 triangular ~hank Or 9.30 grams
~iber length 15 gauge (-072
75% cellulose inches) diameter
crepe waddi~g - 800 needle holes
10 lb. wgt. per per square inch
3000 ~q. reet 9 barbs per needle.
(10 plies)
~ ,.
lOS;~S02
MATERIAL TRANSFERENCE
V. EMPLOYED METHO~ RESULTS
-L 100~ oellulose Barbed needles Syn yna absorbency
crepe wadding - triangular shank, of ~.8 grams
lO lb. wgt. per 15 gauge (-072
3000 sq. feet inches) diameter
(lO plies) 800 needle holes
per square inch
9 barbs per needle.
It should be noted that a 100~ cellulose crepe sampl-
ing oonstituted of exactly the same materials o~ sample V~ but
not sub~ected to the needle punching has a Syngyna absorben¢y
o~ 8.6 grams. It is o~ interest to note that the ~ibers on
such cellulose crepe wadding are relatively short and non-elastic
and thus d~icult to transfer through to another surface in
great numbers.
MATERIAL TRANSFERENCE
V~. EMPLOYED METHOD ,_ RESULTS
20g polyureth~ne Barbed needles Syngyna absorbency
l/8 inch sheet triangular shank o~ lO.10 grams
(non-absorbent) 15 gauge (.072
80~ cellulose inches diameter)
crepe waddlng 800 needle holes
lO lb. wgt. Per per square inch
3000 8q. reet 9 barbs per needle-
(lO plies)
A polyurethane (non-absorbent) and cellulose crepe wadd-
ing sampling containing no openings ror ~ilament transference
exhibited an absorbency level from two (2) to three (3) per cent
leas than the sample VI sampling above. It i9 also of note that
where a sampling of 80% rayon (3 denier l 9/16 ~iber length) was
combined in a 20~ polyurethane (1'8 inch sheet non-absorbent)
there was a five (5%) per oent increment in absorbency where
openings and ~ilament transference was e~ected by barbed needles
o~ the type indicated in the examples.
.,
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lOSZSQ2
MATE~AL IRANSFERENCE
EMPLOYED METHOD RESULTS
VII. 15% oheese cloth Barbed needles, Syngyna absorbency
100,~ cotton; 85S~ triangular shank Or 9.30 grams
oell~lose crepe 15 gauge (-072
wadding 10 lb. wgt. inches diameter)
per 3000 sq. reet 800 needle holes
(10 plies) per square inch
9 barbs per needle.
lQ A sampling o~ cheese cloth - cellulose crepe wadding
similar to example VII above not sub~ected to needle punohing
exhibited twenty-~ive (25~) per cent less absorbency than the
sample VII material.
As may be noted ~rom the above, not only is there
increased absorbency (Samples I, III, IV, V) but materials here-
to~ore not generally employed in the manufacture of absorbent
material, especially as a constituent material, ~or a rather in-
expensive item such as a tampon (Sample VII) can be made to reach
acceptable absorbency levels ~or use in such products.
It has also been round that it is possible to increase
the absorbency o~ an all rayon tampon. W~ere the constituents
~are layers weighine 2.2 grams o~ rayon, it has been ~ound that
the needle punching operation (i.e., ôOO strokes p.s.i, using
a 15 gauge .072 diameter needle ) spreads the ~ilaments and re-
aligns the ~ilament orientation with a resultant increase in
absorbency levels.
While all o~ the tests above were conductqd employed
800 openings per square inch, tests were conducted at varying
levels rrom 10 openings per square inch to over 1000 openings
per square inch, it being found that on the materials tested
.
range o~ between 600-850 punches per square inch gave best re-
sults.
In addition, increased absorbency occurs both in in-
st~nces where the constituents materials ~re the ~ame and to a
much greater degree where the constituent materials are dis-
similar. Similarly while positive results have been obtained
employing absorbent and non-absorbent combinations, enhanced
-13-
lOS250~
results occur where all of the constituent materials are absor-
bent. All that i9 required however, is that at least one o~
the layers be absorbent and at least one of the layers contain
- filaments having a length sufficient to be effectively transferred
through the openings in one of the constituent materials, atleast
to a su~ficient degree to retain the integrity o~ the openings.
Hence, the absorbency levels of the absorbent composite
is a ~unction of:
(a) the constituent materials
(b) the size of the openings
(c) the number of openings,
(d) the number of rilaments transferred
(e) the denier of filaments, and
(~) speci~ic gravity (density) o~ filaments.
` By selectively varying any of the above such as by in-
creasing the needle size, and/or the number Or barbs per needle,
or increasing the number of openings, or by otherwise affecting
any of the above variables, selective grading of absorbency levels
can be accomplished.
The only ma~or limiting factor (aside ~rom raw mate-
rial cost) would appear to be the ability of the constituents
to withstand the needle punching filament transferenc~ operation.
As such, it is desirable that the transferee layer be o~ a mate~
rial whioh will act well as a matrix to retsin opening~ having
rilaments extending therethrough.
- ~ While the present invention has been described with
particularity in terms o~ its application to a tampon various
other uses are possible. It is to be further appreciated that
~the terms and expressions which have been employed are used for
purposes of ~llustration, it is recognized though that various
modifications are possible within the scope of the invention as
claimed.
.Q~ .
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