Note: Descriptions are shown in the official language in which they were submitted.
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A TAMPON APPLICATOR HAVING A FORCE CONTROLLER
FIELD OF THE INVENTION
The present invention relates to a novel tampon applicator having an expulsion
force controller providing expulsion of a tampon.
BACKGROUND OF THE INVENTION
It is known that the internal vaginal cavity in its normal state has a shape
of a
flattened bag with its minimum width near the introitus and its maximum width
near the
cervix. It is desirable, therefore, when considering a tampon for catamenial
use, to
provide a structure which, in its initial state, is of a size small enough to
pass through the
vaginal orifice without discomfort, and once delivered and placed inside the
vaginal
cavity beyond the restrictions of the orifice, can increase its dimension,
particularly in the
lateral direction, to cover substantially large portions of the vaginal
surface from one side
to the other to prevent early bypass of the menstrual discharges from the
cervix. This
side-to-side coverage is a preferred object of this invention. Further, since
the vaginal
wall in its normal state is flaccid and has multiple folds and wrinkles which
provide
channels through which a significant portion of the menstrual fluids normally
flow, it is
also important that the absorbent tampon be as soft and conformable as
possible to
conform to the shape of the vaginal cavity and fit within these channels to
minimize
leakage.
Generally, absorbent catamenial tampons are small, highly compressed,
cylindrical rigid plugs about 5 to about 20 mm in diameter and from about 35
to about 60
mm in length. Because of the need for absorbent capacity, they are usually
formed from
batts much larger in size than the vaginal orifice and compressed to the small
size
indicated above to facilitate insertion. As fluid is absorbed, these
compressed tampons
are designed to re-expand. While it has been found that these compressed
tampons
perform their intended function tolerably well, even the best of them do not
re-expand
sufficiently, or fast enough, to provide good transverse coverage against
leakage even
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though the vertical blockage may be satisfactory. Further, most of these
tampons often
use only a small portion of their absorptive capacity before leakage. Since
these tampons
rely on some fluid absorption to re-expand, it is clear that fluid bypass and
leakage can
occur prematurely, particularly, immediately or soon after the time of
insertion.
Fortunately, it has been found during development of the present invention
that a
tampon, in particular, a fluid permeable bag tampon, inserted using the tampon
applicator
constructed according to the invention discussed herein yields the side-to-
side coverage
of the vaginal cavity immediately or soon after the time of insertion, even
with no help of
fluid absorption, and thereby can provide even further improvements in leakage
protection, comfort, and low wearing awareness, as compared to currently
marketed
tampon applicators and previous attempts to improve tampon applicators.
SUMMARY OF THE INVENTION
The present invention encompasses a tampon having a bag structure and a tampon
applicator in combination for expulsion of the tampon into a vaginal cavity of
a female
user. The tampon applicator has a tampon holder tube. The tampon applicator
may also
have a plunger. The tampon holder tube comprises a hollow interior portion, an
interior
surface, an exterior surface, a longitudinal axis, an outer perimeter, a first
end
dimensioned for insertion into the vaginal cavity, a second end positioned
oppositely to
the first end, a force controller, and at least one side expulsion member
positioned at the
first end of the tampon holder tube. The side expulsion member has a weakened
region
located at its base. The tampon comprises a fluid permeable bag and absorbent
material
loosely dispersed within the fluid permeable bag.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and
distinctly claiming the subject matter which is regarded as forming the
present invention,
it is believed that the invention will be better understood from the following
descriptions
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wliich are taken in conjunction with the accompanying drawings in which like
designations are used to designate substantially identical elements, and in
which:
FIG. 1a is a perspective view of a tampon applicator and a tampon in its pre-
expelled state.
FIG.1b is a top view of the tampon applicator of FIG.1a.
FIG. 2 is a perspective view of a tampon applicator and a tampon in its
partially-
expelled state.
FIG. 3a is a perspective view of a tampon applicator and a tampon in its
expelled
state.
FIG. 3b is a perspective view of a tampon fitting within the vaginal cavity of
a
female user after the tampon has been expelled by the tampon applicator of the
present
invention.
FIG. 4 is a perspective view of the tanipon before insertion into the tampon
applicator.
FIG. 5a is a perspective view of a bag tampon.
FIG. 5b is a perspective view of an alternative tampon.
FIG. 6a is a perspective view of an alternative embodiment of a tampon
applicator with the tampon.
FIG. 6b is a perspective view of an alternative embodiment of a tampon
applicator with the tampon.
FIG. 7 is a perspective view of an alternative embodiment of a tampon
applicator.
FIG. 8 is a perspective view of an alternative embodiment of a tampon
applicator.
FIG. 9 is a perspective view of an alternative embodiment of a tampon
applicator.
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FIG. 10 is a perspective view of an alternative embodiment of a tampon
applicator.
FIG. 11 is a perspective view of an alternative embodiment of a tampon
applicator.
FIG. 12 is a perspective view of an alternative embodiment of a tampon
applicator.
DETAILED DESCRIPTION OF THE INVENTION
The following are terms which will assist the reader in best understanding the
features
of the invention and not to introduce limitations in the terms inconsistent
with the context
in which they are used in this specification. These definitions are not
intended to be
limiting.
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
therefrom, to aid in wound healing, or for the delivery of active materials,
such as
medicaments, or moisture.
The term "deformable tampon" is meant as a tampon which is easily deformable
and readily deforms generally under a force of less than about 1 pound per
square inch
(hereinafter "psi").
The term "fluid permeable bag tampon" is meant and as seen in FIG. 5a, as a
tampon comprising a fluid permeable bag and absorbent material loosely
dispersed within
the fluid permeable bag, such as that disclosed in U.S. Patent No. 3,815,601,
issued to
Schaefer, on June 11, 1974; U.S. Patent No. 4,278,088, issued to Reeves, et
al., on July
14, 1981; U.S. Patent No. 6,533,771, issued to Suga, et al., on March 18,
2003; and U.S.
Patent Application Serial No. 10/900,950, filed on July 28, 2004, entitled
"Highly
Deformable Tampon," to Thomas Ward Osborn, III, Case 9721.
By the terms "ready position" or "pre-expelled position," it is meant herein
and
as seen in FIG.1a, a position in which the tampon 20 is placed or packed into
the tampon
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holder tube 22 and positioned for the tampon's 20 successful expulsion through
the
tampon holder tube 22.
By the terms "directionally expel," "directed expulsion," or "directional
expulsion," it is meant herein and as seen in FIG. la, that embodiments of the
tampon
5 applicators 21 of the present invention will expel a tampon 20 along the
longitudinal axis
45 and cause it to be placed in a position within the vaginal cavity to expand
outwardly
towards the walls of a female user's vaginal cavity. Such directional
expulsion causes the
tampon applicator 21, when inserted into the vaginal cavity of a female user,
to allow the
tampon 20 to expand in the transverse direction thus providing improved
coverage of a
female user's vaginal cavity.
The term "expelled," as used herein and as seen in FIG. 3a, is meant the
position
after the tampon 20 is forced out of the tampon applicator 21.
By the term "side-to-side coverage," it is meant herein and as seen in FIG. 3b
that the tampon 20 once directionally expelled, will have at least two
sections thereof
positioned outwardly toward the sides or walls of a female user's vaginal
cavity.
By "side expulsion zone" is meant and as seen in FIG. la, a weakened region as
compared to the side expulsion members 31. The side expulsion zone 35 is
located
between a first side expulsion member 31 and a second side expulsion member
31.
By "axial force," is meant and as seen in FIG. la, the force 40 applied along
the
longitudinal axis 45 in the direction of expelling the tampon 20 from the
tampon
applicator 2 1.
Referring to FIG. 1a, the present invention relates to directionally expelling
tampon 20 into the vaginal cavity of a female user from a tampon applicator
21. Before
expulsion of the tampon 20 from the tampon applicator 21, the tampon
applicator 21 has
an initial dimension 54. The tampon applicator 21 herein comprises a tampon
holder tube
22 having a hollow interior portion (not shown), an interior surface (not
shown), an outer
perimeter 42, an exterior surface 25, a longitudinal axis 45, a first end 26
dimensioned for
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insertion into the body cavity (specifically the vaginal cavity of a female
user), a second
end 27 positioned oppositely to the first end 26, and a gripping portion 33.
The first end 26 of the tanipon holder tube 22 further comprises force
controllers
30. The force controllers 30 are positioned adjacent to the side expulsion
members 31.
The weakened regions 61 are located around, at, or near, the base of the side
expulsion
members 31. The weakened regions 61 can extend circumferentially around, at,
or near,
the base of the side expulsion members 31. The force controllers 30 are
separated by
force controller sections 34 which may be between each force controller 30.
The force
controllers 30 and the force controller sections 34 are positioned at the top
44 of the first
end 26. The end of the force controllers 30 may have projections 38.
As noted above, the first end 26 comprises side expulsion members 31 which may
be separated by side expulsion zones 35. The side expulsion members 31 and the
side
expulsion zones 35 are positioned along the outer perimeter 42 of the tampon
holder tube
22. The combination of the force controllers 30, the force controller sections
34, the side
expulsion members 31, and the side expulsion zones 35 is configured to
laterally expand
the tampon 20 during expulsion of the tampon 20 from the tampon applicator 21.
Alternatively, the tampon applicator 21 may include a plunger 29 that is
slidably
mounted in the tainpon holder tube 22 distal to the first end 26. The plunger
29 is
adapted to expel the tampon 20 from the tampon holder tube 22 with an axial
force 40.
However, such user activated expulsion may occur either by a plunger 29,
plunger-like
device, or digitally with a user's finger(s).
To use the tampon applicator 21 of the present invention the user will
typically
hold the tampon holder tube 22 in one hand at the gripping portion 33 on the
same. When
the plunger 29 is present, the user holds the end of the plunger 29, such as
with her thumb
and middle finger, and pushes the plunger 29 inwardly to slide the plunger 29
within the
tampon holder tube 22. In practice, a user pushes the inserted plunger 29
until the entire
tampon 20 is deployed from the tampon applicator 21. The user then pulls the
entire
tampon applicator 21 (i.e., with the plunger 29 inside) out of the user's
vaginal opening.
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The tampon applicator 21 has a pre-expelled state (FIG. la), a partially
expelled
state (FIG. 2), and an expelled state (FIG. 3a). During the pre-expelled
state, as is
readily seen in FIG. la, the tampon 20 sits within the tampon holder tube 22
and can
remain snugly therein without any outside force to sustain its position in the
tampon
holder tube 22. As shown in FIG. la, during the tampon's pre-expelled state,
the force
controllers 30 have the initial dimension 54. FIG. lb shows a top view of the
tampon
applicator 21 with the initial dimension of 54 and an outer perimeter 42. The
force
controllers 30 are separated by force controller sections 34. In addition, the
force
controller 30 may have a central opening 37.
In the partially expelled state, as is readily seen in FIG. 2, the tampon 20
is shown
being directionally expelled with an axial force 40 along the longitudinal
axis 45. When
the axial force 40 is applied, the tampon 20 is pushed toward the first end
26. During this
time, the tampon 20 is held within the tampon applicator 21 by the force
controllers 30.
In one embodiment, the tampon 20 is spread by force controllers 30.
Specifically, when
the axial force 40 is applied, the axial force 40 is transferred to horizontal
spreading force
of the tampon 20 and the consequent separation of the engaged tampon 20. The
force
controllers 30 may contain projections 38. (FIG. la). The force controllers 30
require a
greater axial force 40 than the side expulsion members 31 to expel the tampon
20. FIG. 2
illustrates a tampon 20 partially positioned within and partially positioned
without the
tampon holder tube 22 of the tampon applicator 21 during the act of expulsion
of the
tampon 20. During expulsion, at least one side expulsion member 31 is
expanded.
The combination of the weakened regions 61, force controllers 30, and the side
expulsion members 31 aide the force controllers 30 to change from its first
position with
an initial dimension 54 in its pre-expelled state to its second position (FIG.
2) with side
expulsion members 31 deployed width 55 in its partially expelled state and
finally to a
third position in its fully expelled tampon applicator 21 state (FIG. 3a).
FIG. 3a shows the tampon applicator 21 in its expelled state where the tampon
20
is expelled from the tampon applicator 21 along the longitudinal axis 45. The
tampon
applicator 21 has a tampon holder tube 22. The tampon holder tube 22 has a
first end 26
dimensioned for insertion and a second end 27 opposite the first end 26. The
first end 26
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comprises the force controllers 30, side expulsion members 31, and side
expulsion zones
35. The force controllers 30 may include projections 38 (FIG. la). In its
expelled state,
the tampon 20 is positioned into the vaginal cavity of a female user so that
improved side-
to-side coverage of the vaginal opening is achieved. After the tampon 20 is
inserted
vertically into the vaginal introitus, the tampon 20 may change its
orientation to a
position which is non-parallel to the tampon's 20 pre-expelled vertical
position. As a
result, the tampon's 20 position during insertion could be in a different
orientation from
the tampon's 20 position after insertion into the vaginal cavity. Contact of a
female
user's vaginal walls is a higlily desired characteristic of a tampon 20 when
it is worn
during a female's menstruation period. Menses, whether highly viscous or less
viscous,
when flowing out of the user, follows the geometry of a female user's vaginal
walls. In
other words, menses may substantially flow along the vaginal walls of a female
user.
Regardless of the orientation of the tampon 20 within the vaginal cavity 60,
FIG. 3b
shows how such side-to-side coverage in the vaginal cavity 60 of the tampon 20
and
placement of the trailing edge 53 of the tampon 20 within the vaginal cavity
60 is
expected to occur when using the present tampon applicator 21.
Referring to FIG. 4, the tampon 20 can be inserted into the tampon applicator
21
in any orientation and/or folded in any manner (i.e., concave or convex).
Despite the
orientation of the tampon 20 upon insertion into the tampon applicator 21, the
tampon 20
will still provide effective side-to-side coverage in the vaginal cavity. In
one non-limiting
exanlple, the first portion 49 of the tampon 20 is inserted first into the
second end 27 of
the tampon holder 22 so that the first portion 49 of the tampon 20 expels
first. In yet
another non-limiting example, the second portion 50 of the tampon 20 is
inserted first into
the second end 27 of the tampon holder 22 so that the second portion 50 of the
tampon 20
expels first. FIGS. 5a and 5b show two non-limiting examples of tampons 20.
Referring
to FIGS. 5a and 5b, the tampon 20 has a first portion 49 and a second portion
50. The
second portion 50 of the tampon has a trailing edge 53. A withdrawal string 39
may also
be attached.
FIG. 6a shows an alternative embodiment of a tampon applicator 21 comprising
the tampon holder tube 22 and the plunger 29. The tampon holder tube 22 has a
first end
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26. The first end 26 comprises the side expulsion members 31 and side
expulsion zones
35. To reduce the expulsion force required to bend the side expulsion members
31 open,
a weakened region 61 is formed irito the outer surface of tampon holder 22
around, at, or
near, the base of the side expulsion members 31. The weakened regions 61 can
extend
circumferentially around, at, or near, the base of the side expulsion members
31. In use,
as plunger 29 is pressed inwardly, side expulsion members 31 hinge at the
weakened
regions 61, and the tampon is expelled through the first end 26 of the tampon
holder tube
22. The more the weakened regions 61 allow the side expulsion members 31 to
hinge,
the greater the horizontal spreading of tampon 20.
FIG. 6b shows yet another alternative embodiment of a tampon applicator 21
containing tampon 20 with a plunger 29. The tampon holder tube 22 has a first
end 26.
The first end 26 comprises the force controllers 30, force controller sections
34, side
expulsion members 31, and side expulsion zones 35. Weakened regions 61 are
formed
into the outer surface of tampon holder 22 around, at, or near, the base of
the side
expulsion members 31. The weakened regions 61 can extend circumferentially
around,
at, or near, the base of the side expulsion members 31. The force controller
sections 34
can comprise of weakened regions. FIG. 7 and FIG. 8 show perspective views of
alternative embodiments of tampon applicators 21 having force controllers 30
and side
expulsion zones 35 which can be void. Weakened regions 61 are formed into the
outer
surface of tampon holder 22 around, at, or near, the base of the side
expulsion members
31. The weakened regions 61 can extend circumferentially around, at, or near,
the base of
the side expulsion members 31. Alternatively, FIG. 9 shows another perspective
view of
an alternative embodiment of the side expulsion members 31 which can be one
continuous film or sheet and the force controllers 30 which can be one
continuous film or
sheet. The force controllers 30 which are located at the top 44 of the first
end 26 and the
sides of the side expulsion members 31 may be completely enclosed. Moreover,
FIG. 10
and FIG. 11 show another perspective embodiment of a tampon applicator 21
having an
initial dimension 54. The sides 48 of the side expulsion members 31 which are
located at
the first end 26 may be non-uniform. Weakened regions 61 are formed into the
outer
surface of tampon holder 22 around, at, or near, the base of the side
expulsion members
31. The weakened regions 61 can extend circumferentially around, at, or near,
the base of
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the side expulsion members 31. FIG. 12 shows another perspective embodiment of
a
tampon applicator 21 having projections 38 located on the end of the force
controller 30.
Weakened regions 61 are formed into the outer surface of tampon holder 22
around, at, or
near, the base of the side expulsion members 31. The weakened regions 61 can
extend
5 circumferentially around, at, or near, the base of the side expulsion
members 31.
Below will detail each component of the tampon applicator 21.
I. FORCE CONTROLLER AND FORCE CONTROLLER SECTION
Referring primarily to FIG. la, the force controllers 30 are positioned at the
top
44 of the first end 26. As shown in FIG. lb, each force controller 30 is
separated from
10 the other by respective sections 34. As shown in FIG. la, the force
controllers 30
counter the axial force 40 which is applied along the longitudinal axis 45
when expelling
the tampon 20 from the tampon applicator 21. Thus, the axial force 40 needed
to expel
the tampon 20 along the longitudinal axis 45 requires a greater force to expel
the tampon
through the force controllers 30 than to expel the tampon 20 through the side
15 expulsion members 31.
The force controllers 30 have a pre-expelled position (FIG. la), a partially
expelled position (FIG. 2), and an expelled position (FIG. 3a).
FIG. 2 shows the position of the force controllers 30 when the tampon 20 is
partially expelled. When a tampon 20 is being expelled by an axial force 40
applied
20 along the longitudinal axis 45, the force controllers 30 expand beyond its
initial
dimension 54 along at least one of the side expulsion members 31. The force
controllers
provide resistance to expelling the tampon 20 at the first end 26 thereof. In
the present
invention, the tainpon 20 is deformable which allows the force controllers 30
to reshape
the tampon 20. In other words, the tampon 20 for the lateral dimension change
during
25 expulsion.
The manufacturer of the tampon applicator 21 may vary the width of each force
controller 30, the number of force controllers 30, the distance between each
force
controller 30, and the configuration of the force controllers 30.
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The width of each force controller 30 can vary greatly. As seen in FIG. la,
the
width of each force controller 30 is a function of the length of the outer
perimeter 42 of
the tampon holder tube 22 and the width of the force controller sections 34
which are
located between each force controller 30.
Any number of force controllers 30 may be utilized. Either an even or an odd
number of force controllers 30 can be present. As shown in FIG. la and FIG.
lb,
although three force controllers 30 are shown, additional force controllers 30
may give
more positive engagement of the tainpon 20.
Referring to FIG. la, the distance between each force controller 30 which
extends
along the outer perimeter 42 of the tampon holder tube 22 depends on the
length of the
outer perimeter 42 of the tampon holder tube 22, the width of each force
controller 30,
and the width of the force controller sections 34 which are located between
each force
controller 30. Moreover, the force controllers 30 can be equally spaced apart
or they can
be non-uniformly arranged. Uniformly arranged force controllers 30 are
preferred, but
randomly arranged force controllers 30 will work. For ease of manufacturing,
it is
preferred that the force controllers 30 be equally spaced relative to one
another. The
force controllers 30, however, may be unequally spaced relative to one
another.
Referring to FIG. la, it is further noted herein that the shape or
configuration of
each of the force controllers 30 may vary as long as the force controllers 30
provides
enough resistance when applying an axial force 40 in the longitudinal
direction 45 to
allow a substantial portion of the tampon 20 to be generally released at one
time. One of
skill in the art will readily recognize obvious variants on those presented in
the patent
application herein. One versed in the art can imagine that the shape of the
force
controllers 30 might be circular, square, rectangular, triangular, arced,
curved, or any
other conceivable shape possible as long as any such shape would work
effectively to
fully and properly provide resistance of the tampon 20 upon expulsion from the
tampon
holder tube 22, expel the tampon 20 from the tampon holder tube 22, and
provide a
greater axial force 40 to expel the tampon 20 along the longitudinal axis 45
from the force
controllers 30 than from the side expulsion members 31. The force controller
30 is in no
way limited by the size or shape that they may assume except that they should
not
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substantially hinder directional expulsion of a tampon 20. As shown in FIG.
6b, in an
alternative embodiment, the side expulsion members 31 may be covered with a
thin film
material which is not as strong as the force controllers' 30 material. The
side expulsion
members 31 could be hinged; scored; and/or could be a thin film. As also shown
in FIG.
6b, the material of the force controllers 30 can be a polyethylene film and
the side
expulsion zones 35 can comprise of weakened regions as compared to the side
expulsion
members 31 which are perforated such that the force controllers 30 provide
resistance to
the tampon 20 while the plunger 29 forces the tampon 20 out of the force
controllers 30.
Referring to FIG. ib, the force controller sections 34 which separate each
force
controller 30 can be void areas, weakened regions, and/or regions covered in
material. If
the force controller sections 34 are covered in material, the material of the
force
controller sections 34 are not as strong as the force controllers' 30
material.
In one non-limiting example, the outer perimeter 42 can be about 60.96 mm. In
this example, there can be three force controllers 30. Additionally, each
force controller
30 can be about 6.35 mm and the force controller sections 34 between each
force
controller 30 can be about 13.97 mm.
In yet another non-limiting example, the outer perimeter 42 can be about 75
mm.
In this example, there can be five force controllers 30. Additionally, each
force controller
30 can be about 6.35 mm and the force controller sections 34 between each
force
controller 30 can be about 8.65 mm.
In one further non-limiting example, the outer perimeter 42 can be about 53.5
mm.
In this example, there can be six force controllers 30. Additionally, each
force controller
can be about 8 mm and the force controller sections 34 between each force
controller
30 can be about 1 mm.
25 As shown in FIG. la, each force controller 30 may comprise projections 38.
The
projections 38 may extend far enough into the center of the first end 26 to
engage a
tampon 20 disposed therein. The projections 38 may be any shape or size so
long as the
projections 38 provide resistance to expelling the tampon 20 by increasing the
difficulty
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of expelling the tampon 20 out of the first end 26 thereof. The projections
may take the
form of a variety of shapes such as a rib, a notch, a knob, a hook, a
perforation, an
adliesive, VELCRO , a bump, a ridge, or any mixtures thereof. In yet another
example,
the projections 38 may be inward, outward, or substantially straight. As shown
in FIG.
12, the projections 38 may be integrally formed on the end of each force
controller 30.
Alternatively, the projections 38 may be separately attached to the force
controller 30.
As shown in FIG. la, any number of projections 38 may be utilized. Either an
even or an odd number of projections 38 can be present. The number of
projections 38
may vary as desired. Additional projections 38 may give more positive
engagement of
the tampon 20.
The projections 38 may be located anywhere on the force controllers 30. As
shown in FIG. la, the projections 38 may be located at the end of the force
controller 30.
Furthermore, each force controller 30 does not have to have a projection 38.
Referring to FIG. 1a, as axial force 40 is applied along the longitudinal axis
45,
the projections 38 retain the tampon 20 while forcing the force controllers 30
to expand
beyond its initial dimension 54 in its pre-expelled state. The projections 38
(FIG. la)
allow the tampon 20 to laterally expand into the vagina and provide better
vaginal
coverage. Projections 38 (FIG. la) located at the end of the force controller
30
especially complement deformable tampons 20 which require less pressure to
expand
upon expulsion from the tampon holder tube 22.
As shown in FIG. lb, the top view of the tampon holder tube 22 (FIG. la) forms
a substantially rounded tip. The tampon holder tube 22 may have a central
opening 37 at
the top 44 (FIG. la) of the first end 26 (FIG. la). As shown in FIG. la, the
rounded
shape is useful to facilitate insertion of the tampon applicator 21 into the
vaginal cavity.
As shown in FIG. 7, in an alternative embodiment, the force controllers 30
form a
substantially closed end configuration.
While not wishing to be bound by any particular theory, the force controllers
30
may be made from any polymeric material such as polyethylene, polypropylene,
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polybutylene, polystyrene, polyvinylchloride, polyacrylate, polymethacrylate,
polyacrylnitril, polyacrylamide, polyamide, nylon, polyimide, polyester,
polycarbonate,
ethylene vinyl acetate, polyurethane, silicone, derivatives thereof,
copolymers thereof,
mixtures thereof, and the like. The force controller 30 may also be made of
paper,
paperboard, cardboard, or any combinations thereof. Each force controller 30
may be
composed of different materials or may be composed of substantially the same
type of
material. The force controller 30 need not be of the same material as the body
of the
tampon applicator 21.
The maximum width in which the tampon 20 is spread before leaving the tampon
applicator 21 of the present invention is from about 20 mms to about 60 mms,
depending
on the tampon design.
II. SIDE EXPULSION MEMBER AND SIDE EXPULSION ZONE
Referring primarily to FIG. la, the side expulsion members 31 aid in the
trajectory of the tampon 20 because the side expulsion members' 31 axial force
40 to
expel the tampon 20 is less than the axial force 40 to expel the tampon 20
from the force
controllers 30. Because the side expulsion members' 35 axial force 40 is less,
this aids in
tampon's 20 proper placement which provides side-to-side coverage in the
vaginal cavity.
The axial force 40 is less because of the lack of resistance of the tampon 20
to move
between the side expulsion members 31 as compared to the force controllers 30.
In fact,
when the tampon 20 is being expelled from the tampon holder tube 22, the force
controllers 30 provide resistance while the side expulsion members' 31 reach a
deployed
width 55 (FIG. 2).
To reduce the expulsion force required to bend the side expulsion members 31
open, a weakened region 61 is formed into the outer and/or inner surface of
tampon
holder 22 around, at, or near, the base of the side expulsion members 31. The
weakened
regions 61 can extend circumferentially around, at, or near, the base of the
side expulsion
members 31. In use, as plunger 29 is pressed inwardly, side expulsion members
31 hinge
at the weakened regions 61, and the tampon is expelled through the first end
26 of the
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tampon holder tube 22. The more the weakened regions 61 allow the side
expulsion
members 31 to hinge, the greater the horizontal spreading of tampon 20.
The weakened regions 61 may take a variety of forms such as differential wall
thickness, grooves, perforations, slots, T-cuts, V-cuts, hinges, and mixtures
thereof.
5 The weakened regions 61 can be any size or shape. Weakened regions 61 can be
any size or shape as long as the weakened region 61 is able to reduce the
force required to
bend the side expulsion meinber 31. The weakened region 61 can be circular,
square,
rectangular, triangular, arced, curved, or any other conceivable shape
possible. While the
weakened regions 61 can be a wide range of shapes, it is preferred to use a
member
10 selected from the group consisting of straight grooves, tapered grooves,
rectangular,
flower petals, ellipses, and mixtures thereof.
The weakened regions 61 may be formed to have essentially identical sizes and
shapes. In one non-limiting example, the tampon holder tube comprises ten
weakened
regions 61. In this example, each weakened region 61 can be identical to the
other
15 weakened regions 61. Alternatively, the weakened regions 61 may be formed
to have
various sizes and shapes as compared to another weakened region 61 on the
tampon
holder tube. In one non-limiting example, the tampon holder tube 22 has five
weakened
regions 61. However, each weakened region 61 may have a different geometric
shape.
Additionally, each weakened region 61 may have a different size.
The number of weakened regions 61 and the distance over which the weakened
regions 61 extend may vary. Typically, the weakened regions 61 are formed at
the base
of the side expulsion members 31. The number of side expulsion meinbers 31 may
range
from about 1 to infinity. Either an even or an odd number weakened regions 61
can be
present. For ease of manufacturing, it is preferred that the weakened regions
61 be
equally spaced relative to one another. The weakened regions 61, however, may
be
unequally spaced relative to one another.
The distance between each weakened region 61 depends upon the area of the side
expulsion members 31 and the size and number of weakened regions 61.
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More than one weakened region 61 can be formed at the base of the side
expulsion members 31. If more than one weakened region 61 is formed, the
weakened
regions 61 may be arranged randomly or in a pattern. For example, weakened
regions 61
can be arranged to form any three-dimensional geometric pattern known
including but not
limited to diagonal lines, straight lines, checkerboard, flowers, ovals,
circles, rectangles,
trapezoids, triangles, cones, alphabet letters, and mixtures thereof.
Alternatively, the
weakened regions 61 may be along the full length of the base of the side
expulsion
member 31 or may have thinned regions spaced intermittently along the length
of the
base of the side expulsion meinber 31. Alternatively, weakened regions 61 may
be
randomly arranged so that the multiplicity of weakened regions 61 may comprise
merely
a surface roughness in no apparent pattern. In addition, weakened regions 61
may be
arranged such that the areas between the weakened regions 61 may form any
geometric
pattern known including but not limited to flowers, ovals, circles,
rectangles, trapezoids,
triangles, cones, alphabet letters, and mixtures thereof.
The side expulsion members 31 are positioned around the outer perimeter 42 of
the tampon holder tube 22. The side expulsion members are below and adjacent
to the
force controllers 30. The side expulsion members 31 are separated from each
other by
respective side expulsion zones 35.
The side expulsion members 31 have a pre-expelled position with a side
expulsion
zone initial dimension 54 which is less than or equal to the outer perimeter
42 of the
tampon holder tube 22. Furthermore, the side expulsion members 31 also have a
side
expulsion zone deployed width 55, shown in FIG. 2, which is greater than the
outer
perimeter 42 (FIG. 1) of the tampon holder tube 22 and the side expulsion
zone's initial
dimension 54. In other words, the side expulsion members 31 expand from a
first
transverse width 54 to a second transverse width 55. The second transverse
width 55 is
greater than the first transverse width 54. In one non-limiting example, the
side expulsion
members 31 may have a side expulsion zone initial dimension 54 of about 5/8
inch (about
1.6 cm) and a side expulsion zone deployed width 55 of about 3/4 inch (about
1.9 cm) to
about 1'/4 inch (about 3.2 cm).
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FIG. 2 shows the side expulsion members 31 when the tampon 20 is partially
expelled. FIG. 3a shows the side expulsion members 31 in its expelled
position.
The manufacturer of the tampon applicator 21 may vary the configuration of
each
side expulsion member 31, the number of side expulsion members 31, the width
of each
side expulsion member 31, and the distance between each side expulsion member
31.
Referring to FIG. la, the configuration of the side expulsion members 31 is
preferably created to decrease the weakness along a portion of outer perimeter
42 of the
tampon applicator 21. It is further noted herein that the shape or
configuration of the side
expulsion members 31 may vary as long as a substantial portion of the tampon
20 is
allowed to expel and not hinder directional expulsion of the tampon 20. One of
skill in
the art will readily recognize obvious variants on those presented in the
patent application
herein. One versed in the art can imagine that the side expulsion members 31
might be
circular, square, rectangular, triangular, or any other conceivable shape
possible as long
as any such shape would work effectively to fully and properly aide in the
expulsion of
the tampon 20 from the tampon holder tube 22. As shown in FIG. 10 and FIG. 11,
the
sides 48 of the side expulsion members 31 may be non-uniform.
Referring to FIG. la, any number of side expulsion members 31 may be utilized.
Either an even or an odd number of side expulsion members 31 can be present.
As shown
in FIG. ib, three side expulsion members 31 are shown.
Referring to FIG. 1a, the width of each of the side expulsion member 31 can
vary
greatly. The width of each side expulsion member 31 is a function of the outer
perimeter
42 of the tampon holder tube 22 and the width of the side expulsion zones 35.
Referring to FIG. la, the distance between each side expulsion member 31 which
extends along the outer perimeter 42 of the tampon holder tube 22 depends upon
the outer
perimeter 42 of the tampon holder tube 22, the width of the each side
expulsion member
31, and the width of the side expulsion zones 35. They can be equally spaced
apart or
they can be non-uniformly arranged. Uniformly arranged side expulsion members
31 are
preferred, but randomly arranged side expulsion members 31 will work. For ease
of
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manufacturing, it is preferred that the side expulsion members 31 be equally
spaced
relative to one another. The side expulsion members 31, however, may be
unequally
spaced relative to one another.
The side expulsion members 31 are separated by side expulsion zones 35. The
side expulsion zones 35 can be void areas, weakened regions, perforated areas,
and/or
thin areas. As shown in FIG. 6b, the configuration of the side expulsion
members 31
may be one continuous sheet with wealcened regions as side expulsion zones 35.
As
shown in FIG. la, the side expulsion members 31 may be separated from one
another by
void side expulsion zones 35.
In one non-limiting example, the outer perimeter 42 of the tampon holder tube
22
can be about 60.96 mm. In this example, there can be three side expulsion
members 31.
Additionally, each side expulsion member 31 can be about 6.35 mm and the side
expulsion zones 35 between each side expulsion member 31 can be about 13.97
mm.
In yet another non-limiting example, the outer perimeter 42 of the tampon
holder
tube 22 can be about 75 mm. In this example, there can be five side expulsion
members
31. Additionally, each side expulsion member 31 can be about 6.35 mm and the
side
expulsion zones 35 between each side expulsion member 31 can be about 8.65 mm.
In
this example, the length of the side expulsion members 31 and the side
expulsion zones
35 can be about 35.56 mm.
In one further non-limiting example, the outer perimeter 42 can be about 53.5
mm.
In this example, there can be six side expulsion members 31. Additionally,
each side
expulsion members 31 can be about 8 mm and the side expulsion zones 35 between
each
side expulsion member 31 can be about 1 mm. In this example, the length of the
side
expulsion members 31 and the side expulsion zones 35 can be about 20 mm.
FIG. 6a shows an alternative embodiment of a tampon applicator 21 comprising
the tampon holder tube 22 and the plunger 29. The tampon holder tube 22 has a
first end
26. The first end 26 comprises the side expulsion members 31 and side
expulsion zones
35. To reduce the expulsion force required to bend the side expulsion members
31 open,
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a weakened region 61 is formed into the outer surface of tampon holder 22
around, at, or
near, the base of the side expulsion members 31. The weakened regions 61 can
extend
circumferentially around, at, or near, the base of the side expulsion members
31. In use,
as plunger 29 is pressed inwardly, side expulsion members 31 hinge at the
weakened
regions 61, and the tampon is expelled through the first end 26 of the tampon
holder tube
22. The more the weakened regions 61 allow the side expulsion members 31 to
hinge,
the greater the horizontal spreading of tampon 20.
In an alternative embodiment, as seen in FIG. 9, the side expulsion members 31
may have one continuous film or sheet and the force controllers 30 may have
one
continuous film or sheet. The sheet of the force controllers 30 may completely
enclose
the top 44 of the first end 26. The sheet or film of the side expulsion
members 31 may
completely enclose the sides. The sheet of the side expulsion members 31 and
the sheet
of the force controller 30 may overlap one another. The sheet for the side
expulsion
members 31 and the sheet for the force controllers 30 can be sealed to one
another by any
known means in the art such as heat seal, glue, or mold. This film or sheet
protects the
tampon 20 from contamination. The sheet or film for the side expulsion members
31 is
not as strong as the film or sheet for the force controllers' 30 material.
The side expulsion members 31 may be composed of different materials or may be
composed of substantially the same type of material.
III. TAMPON
The present invention may be used with any type of tampon. As used herein, the
term "tampon" refers to any type of absorbent structure that can be inserted
into the
vaginal cavity or other body cavities for the absorption of fluid therefrom or
for the
delivery of active materials, such as medicaments or moisture. A tanlpon can
be straight
or non-linear in shape, such as curved along the longitudinal axis.
Generally, there are two types of tampons. The first type of tampon is a self-
sustaining tampon. Tampons are generally "self-sustaining" in that they will
tend to
retain their general shape and size before use. A typical self-sustaining
tampon is 35 - 60
mm long, the length measured from the top of the tampon to the base of the
tampon along
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a longitudinal axis. The measurement to the base of the tampon does not
include any
overwrap, secondary absorbent member, or withdrawal cord which extends beyond
the
tampon's main absorbent material. A typical self-sustaining tampon is 5 - 20
mm wide
corresponding to the largest cylindrical cross section. The width can vary
along the
5 length of the self-sustaining tampon.
The second type of tampon is a deformable tampon. Such a deformable tampon
can easily deform generally under a force of less than about 1 psi applied or
released.
The deformable tampon may comprise any material which exhibits bulkiness,
resiliency,
flexibility, compressibility, or twistability. The deformable tampon may
comprise any
10 structure which includes unfilled volume, void, perforation, slit, pleat,
tab, ribbon, fringe,
flare, bellows, fold, wrinkle, segmentation, and the likes, generating
deformability of the
tampon. When expelled from the tampon applicator of the present invention into
the
vaginal cavity, such a deformable tampon tends to deform, spread, open or
expand inside
the vaginal cavity during the insertion primarily in the lateral direction of
the vaginal
15 cavity and, thus provides the side-to-side coverage of the vaginal cavity.
Unlike the
highly compressed rigid tampon, the deformable tanipon also provides a fit to
the
channels in the vaginal wall and leads to further improvement of leakage
protection.
Referring to FIG. 5a, one example of such a deformable tampon is a "fluid
permeable bag tampon" (hereinafter "bag tampon"). The bag tampon consists of,
but
20 is not limited to, discrete pieces such as absorbent chips, spheres, or
fibers contained in a
fluid permeable bag, such as that disclosed in U.S. Patent No. 3,815,601,
issued to
Schaefer, on June 11, 1974; U.S. Patent No. 4,278,088, issued to Reeves, et
al., on July
14, 1981; U.S. Patent No. 6,533,771, issued to Suga, et al., on March 18,
2003; and U.S.
Patent Application Serial No. 10/900,950, filed on July 28, 2004, entitled
"Highly
Deformable Tampon," to Thomas Ward Osborn, III, Case 9721.
The material used for the bag tampon 22 is preferably soft and flexible. In
its pre-
assembled state, the bag tampon 22 is rectangular in shape. However, other
shapes for
the bag tampon 22, such as, but not limited to, trapezoidal, triangular,
hemispherical,
chevron, hourglass, cylindrical, spherical, rectangular, and circular may also
be used.
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There are many possible compositions for the bag tampon 22 including woven and
non-woven materials; polymeric materials such as apertured formed
thermoplastic films,
apertured plastic films, and hydroformed thermoplastic films; porous foams;
reticulated
foams; and reticulated thermoplastic films and thermoplastic scrims. Other
suitable
materials can be comprised of natural fibers (e.g., treated wood, rayon, or
cotton fibers);
synthetic fibers (e.g., polymeric fibers such as polyesters, rayon,
polyethylene, or
polypropylene fibers); or a combination of natural and synthetic fibers. If
the material
comprises a nonwoven material, it can be made by any suitable process. Other
suitable
materials include hydroentangled materials and any other suitable material
known and
typically used in disposable absorbent articles intended for in vivo use.
Typical bag tampons 22 may comprise cotton, rayon, folded tissues, woven
materials, non woven webs (e.g., hydroentangled webs and air laid webs),
synthetic,
natural fibers, or sheeting. The bag tampon 22 may comprise a single material
or a
combination of materials. In one non-limiting embodiment, the bag tampon 22
comprises
rayon, cotton, or coiubinations of both materials. These materials have a
proven record of
suitability for use in the human body. The rayon may be any suitable type
typically used
in disposable absorbent articles intended for in vivo use. Such acceptable
types of rayon
include GALAXY rayon (a tri-lobed rayon fiber) available from Kelheim Fibres
GmbH,
Kelheim, Germany; DANUFIL rayon (a round cross-section rayon fiber), also
available
from Kelheim Fibres GmbH, Kelheim, Germany is also suitable.
The absorbent material can take many physical forms including particles,
fibers,
agglomerates, powders, gels, foams, beads, and mixtures thereof. Sizes of
particles range
from fine powders to about 8 mm. The dimensions of materials are measured
without a
confining pressure. The absorbent materials may be of any shape known in the
art
including but not limited to rods, cones, spheres, squares, chevrons,
cylindrical, ovate,
rectangular, trapezoidal, triangular, or amorphous. The absorbent materials
may be
comprised of one material or may include blends of materials. Blends may
include
different materials, different sized particles, or different shaped particles.
For example,
one embodiment may include a blend of the same type of material with different
sizes and
different shapes. Another embodiment may include a blend of different type of
materials
of the same size and same shape. The surface charges of absorbent materials
may be the
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same or different. Moreover, the non-absorbent material may also be mixed or
blended
with the absorbent material.
Gel compositions may be used for the absorbent material. Such gel compositions
may include polyacrylamide super-absorbent premixed in water or glycerin to
gel.
Various absorbent foams can be used as the absorbent material. These foams may
be relatively thin, collapsed, polymeric foam materials which expand and
absorb body
fluid upon contact with aqueous body fluids. The absorbent material may
comprise an
open celled foam of the "High Internal Phase Emulsion"( hereinafter "HIPE")
type or
may also include "Thin after Drying" (hereinafter "TAD"). Such foam materials
have
cells and holes small enough to provide a high capillary absorptive pressure,
but large
enough to prevent or minimize blockage by the insoluble components of blood
and blood
based liquids such as menses. Such suitable foams are disclosed in U.S. Patent
No.
5,387,207. Suitable foams or combinations of foams may include those materials
where
the ratio of absorbencies measured at 0 psi and 0.25 psi (e.g., .25 psi
absorbency/ 0 psi
absorbency) are greater than 0.5.
If a mixture of materials is used, the surface charges of the materials may be
the
same or different. The difference in surface charges may be altered via the
addition of
charged polymers to the outer surface of the particles or by using cationic
absorbents.
For example, in one embodiment, a quatinized chitosan may be used in
combination with
a HIPE foam.
Referring to FIG. 5b, another example of such deformable tampons is a tassel
tampon comprising a plurality of absorbent strips or cords, such as that
disclosed in
currently pending and commonly assigned, U.S. Patent Application Serial No.
10/836,892, filed on April 30, 2004, entitled "Tampon Comprising a Plurality
of Strips or
Cords," to Minoguchi, et al, Case 9615.
IV. TAMPON APPLICATOR MATERIALS
Different tampon applicator parts can be constructed from different materials
and
processes.
A. Tarnpon Holder Tube Materials
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Referring primarily to FIG. la, the tampon holder tube 22 can be constructed
from similar materials to other tampon holder tubes 22 known in the art of the
type used
in tampon applicators currently in use. Examples of other such tampon holder
tubes are
disclosed in U.S. Patent No. 5,346,468 issued to Campion, et al. on September
13, 1994
and U.S. Patent No. 5,558,631 issued to Campion, et al. on September 24, 1996.
The
tampon holder tube 22 can be of any suitable cross-sectional shape. Suitable
cross-
sectional shapes include, but are not limited to circular, oval, flattened
circular, and
elliptical. Preferably, the tampon holder tube 22 has a circular cross-
sectional
configuration. Moreover, the tampon holder tube 22 may be made from any
polymeric
material such as polyethylene, polypropylene, polybutylene, polystyrene,
polyvinylchloride, polyacrylate, polymethacrylate, polyacrylnitril,
polyacrylamide,
polyamide, nylon, polyimide, polyester, polycarbonate, ethylene vinyl acetate,
polyurethane, silicone, derivatives thereof, copolymers thereof, mixtures
thereof, and the
like. The tampon holder tube 22 may also be made of paper, paperboard,
cardboard, or
any combinations thereof. Accordingly, the exterior surface 25 of the tampon
applicator
21 may be constructed from any suitable smooth plastic material.
B. Plunger Materials
Referring primarily to FIG. la, the plunger 29 can be used to expel the tampon
20
from its position within the tampon holder tube 22 when the plunger 29 is
pushed
manually into the tampon holder tube 22. The plunger 29 is usually pulled out
to its
operative position when the tampon holder tube 22 is placed in the vaginal
cavity.
Plunger 29 is then telescoped back into the tampon holder tube 22 towards the
second end
27 thereof, pushing the tampon 20 through the first end 26 spreading open the
yieldable
force controller 30 and side expulsion zone(s) 31.
The plunger 29 can be any type of component that is suitable for this purpose.
The
plunger 29 can be constructed similarly to plungers of the type used in tampon
applicators
currently in use. An example of a suitable plunger is disclosed in U.S. Patent
No.
5,346,468 issued to Campion, et al. on September 13, 1994 and U.S. Patent No.
5,558,631
issued to Campion, et al. on September 24, 1996. Moreover, the plunger 29 may
be made
from any polymeric material such as polyethylene, polypropylene, polybutylene,
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polystyrene, polyvinylchloride, polyacrylate, polymethacrylate,
polyacrylnitril,
polyacrylamide, polyamide, nylon, polyimide, polyester, polycarbonate,
ethylene vinyl
acetate, polyurethane, silicone, derivatives thereof, copolymers thereof,
mixtures thereof,
and the like. The plunger 29 may also be made of paper, paperboard, cardboard,
or any
combinations thereof.
It should also be understood that the plunger 29 is an optional component for
use
with the tampon applicator 21 and that the tampon applicator 21 will be fully
functional if
the plunger 29 is omitted, i.e., a user must insert and push the tainpon 20
through the
tampon applicator 21 digitally.
All documents cited in the Detailed Description of the Invention 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. To
the extent that
any meaning or definition of a term in this written document conflicts with
any meaning
or definition of the term in a document incorporated by reference, the meaning
or
definition assigned to the term in this written docunlent shall govern.
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.
It is therefore intended to cover in the appended claims all such changes and
modifications that are within the scope of this invention.
