Note: Descriptions are shown in the official language in which they were submitted.
COMPACT TAMPON APPLICATOR
This application claims the benefits of U.S. Provisional Patent Application
No.
62/754,443 filed on November 1, 2018, the contents of which are incorporated
herein by
reference.
FIELD OF THE INVENTION
The present invention relates to tampon applicators and particularly tampon
applicators
that provide a compact and unobtrusive form that is easy to manufacture and
use.
BACKGROUND OF THE INVENTION
Numerous designs for tampon applicators that introduce tampons or pledgets
intravaginally
have been disclosed in the art and many are currently sold commercially. Most
tampon applicator
designs employ an outer open ended tubular holder or barrel that holds a
tampon or pledget within
the inner tubular cavity and a plunger adapted to move within the inner
tubular cavity of the outer
barrel to expel the tampon or pledget from the outer barrel. The plunger is
also generally tubular,
though smaller in diameter than the inner tubular cavity of the outer barrel,
and is telescopically
positioned therein so that by moving the plunger into one end of the outer
barrel, the tampon or
pledget may be ejected from the opposite end. Many of these prior and
commercially available
designs assemble the tampon applicator by placing the plunger and tampon or
pledget into the top
or insertion tip of the outer barrel and then subjecting the assembled
structure to further processing
to close the insertion tip. Examples of various tampon applicator designs can
be found in U.S.
Patent Nos. 3,895,634; 4,291,696; 5,533,966; 6,019,744; 6,432,075; 6,773,422;
7,704,242;
8,372,027; 8,444,590; 9,192,522; 9,339,419 and 9,737,443.
Although the various prior art tampon applicators work for their intended
function, i.e., the
insertion and placement of a tampon or pledget into the vagina, there is
always a need to improve
upon the prior designs. In particular there is a need for a compact and easy
to manufacture tampon
applicator that is also comfortable and easy to use.
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SUMMARY OF THE INVENTION
The foregoing need is met by the present invention, which is a compact tampon
applicator
that is easy to manufacture and easy to use.
More specifically, the present invention is a tampon applicator comprising an
outer barrel
with an insertion end and a gripping end opposite the insertion end, a tampon
or pledget within the
inner cavity or inner portion of the outer barrel, and a plunger which pushes
the tampon or pledget
through the inner cavity of the outer barrel and out of the inner cavity of
the outer barrel through
the insertion end of the outer barrel.
In one embodiment the plunger is a folded or segmented plunger with a first
portion of the
plunger located within the inner cavity (inside) of the outer barrel near the
gripping end of the
applicator prior to use and a second portion of the plunger located outside
the inner cavity of the
outer barrel prior to use. The first portion of the plunger has a pledget
contact end that is inside the
gripping end of the outer barrel and will contact the base of the pledget
inside the outer barrel. The
first portion of the plunger will also have a connection end that is opposite
the pledget contact end
and connected to the second portion of the plunger. The second portion of the
plunger has a
connection end that is connected to the connection end of the first portion of
the plunger, and a
push end that is opposite the connection end. During storage and/or prior to
use, the second portion
of the plunger is located outside the inner cavity of the outer barrel with
the connection end near
the gripping end of the barrel and the push end near the insertion end of the
outer barrel. In
preparation for use, the push end of the second portion of the plunger is
moved away from the
insertion end of the outer barrel preferably in a radial manner to a position
that creates a continuous
longitudinal axis between the first portion of the plunger and the second
portion of the plunger
with the second portion of the plunger extended away from the gripping end of
the outer barrel.
Once the second portion of the plunger is in a continuous longitudinal axis
orientation with the
first portion of the plunger, the user can exert pressure on the push end of
second portion of the
plunger towards the insertion end of the outer barrel and slide the pledget
contact end of the first
portion of the plunger into contact with the pledget (if not already in
contact) and push the pledget
through the insertion end of the outer barrel.
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In another embodiment of the present invention, the plunger is substantially
encompassed
by the outer barrel during storage or prior to use and the pledget is
substantially encompassed by
the plunger which is substantially encompassed by the outer barrel during
storage or prior to use.
In this embodiment, the outer barrel has an insertion end and a gripping end
opposite the insertion
end. The plunger has an insertion end and a push end that is opposite the
insertion end. The
plunger is sized to fit within the interior of the outer barrel with the
insertion end of the plunger
located near the insertion end of the outer barrel prior to use and the push
end of the plunger located
near the gripping end of the outer barrel. The push end of the plunger extends
away from the
gripping end of the outer barrel. In preparation for use, the plunger is moved
from a nested position
wherein a substantial portion of the plunger is encased within the outer
barrel, by pulling the push
end of the plunger away from the gripping end of the outer barrel along a
longitudinal axis of the
outer barrel and plunger to a ready to use position. Once the plunger is in
the ready to use position,
the insertion end of the plunger engages the base of the pledget that is
opposite the insertion tip of
the pledget. Once the insertion end of the plunger engages the base of the
pledget, the user can
exert pressure on the push end of the plunger towards the insertion end of the
outer barrel and push
the pledget through the insertion end of the outer barrel.
In a further embodiment, the present invention is a tampon applicator
comprising an outer
barrel with an insertion end and a gripping end opposite the insertion end, a
tampon or pledget
within the inner cavity (inside) of the outer barrel, and a plunger which
pushes the tampon or
pledget through the inner cavity of the outer barrel and out of the inner
cavity of the outer barrel
through the insertion end of the outer barrel wherein the applicator can be
easily manufactured by
forming the outer barrel with a desired shape and design at the insertion end,
inserting the tampon
and/or the pledget into the gripping end of the outer barrel opposite the
preformed insertion end.
The tampon or pledget may be inserted separately or simultaneously with the
plunger.
BRIEF DESCRIPTION OF THE DRAWING
Figures 1 A to 1G show embodiments of a tampon applicator of the present
invention
wherein Figure 1A shows the individual parts of an embodiment, Figure 1B shows
side views of
the assembled applicator in a storage or prior to use mode, Figure 1C shows a
side view of the
assembled applicator in a ready to use mode, Figure 1D shows a top view of the
assembled
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applicator in a storage or prior to use mode, Figure 1 E shows side cross
sectional views taken
along line A-A of Figure I D of the assembled applicator in various stages of
the use mode
including the final stage of the use mode wherein the pledget has been pushed
through the insertion
tip of the outer barrel and Figures 1F and 1G shows alternative embodiments of
the plunger shown
in Figure IA.
Figures 2A to 2H show another embodiment of a tampon applicator of the present
invention
wherein Figure 2A shows the individual parts of the embodiment, Figures 2B, 2C
and 2D show
side views of the assembled applicator in a storage or prior to use mode,
Figure 2E shows a side
view of the assembled applicator in a ready to use position, Figure 2F shows
the assembled
applicator after the pledget has been pushed from the insertion tip, Figure 2G
shows a top view of
the assembled applicator and Figure 2H shows a side cross sectional view of
the assembled
applicator in a storage or prior to use mode taking along line A-A of Figure
2G.
Figures 3A to 3C show a further embodiment of a tampon applicator of the
present
invention, Figures 3A shows a side view of the assembled applicator in a
storage or prior to use
mode, Figure 3B shows a side view of the assembled applicator in a ready to
use position, Figure
3C shows the assembled applicator after the pledget has been pushed from the
insertion tip.
DETAILED DESCRIPTION OF THE INVENTION
The tampon applicator of the present invention may be made by any means
commonly
known in the art such as injection molding, preferably by injection molding
the outer barrel in a
single injection molded piece and injection molding the plunger in a single
injection molded piece
or in multiple injection molded pieces.
The outer barrel and plunger may be made of any material that may be injection
molded or
commonly used for tampon applicators such as thermoplastics, cellulose based
materials,
biopolymers, etc. Examples of materials that may be used include but are not
limited to
polyolefins such as polyethylene and polypropylene (including polyolefin
copolymers); polyesters
such as polyethylene terephthalate; polyamides such as nylon; polyurethanes;
polystyrene;
polycaprolactone; polyvinyl alcohol; ethylene-vinyl acetate copolymers;
elastomers such as
silicones, natural rubbers, and synthetic rubbers including block copolymers;
cellophane; cellulose
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materials such as hydroxypropyl methylcellulose and hydroxypropyl cellulose,
starches,
polyethylene oxides and combinations thereof. Examples of some of these
materials can be found
in U.S. Patent Nos. 9,339,580, 6,773,422 and 5,910,520 and International
Patent Application No.
WO 2002/07352 which are incorporated herein by reference.
The pledget employed in the tampon applicator of the present invention may be
made of
any absorbent material having acceptable absorbency and modulus of elasticity
properties capable
of absorbing and/or retaining liquid. The absorbent structure can be
manufactured in a wide variety
of sizes and shapes and from a wide variety of liquid-absorbing materials. It
is, of course, desirable
to use absorbent materials having a minimum content of extraneous soluble
materials since the
product may be retained in the body for a considerable period of time, i.e.,
absorbent materials that
contain little or preferably no unnecessary soluble matter which could
dissolve and enter the body.
Retained soluble extraneous materials could cause a safety hazard if they are
toxic, irritant, or
sensitive. A representative, non-limiting list of useful absorbent materials
includes cellulosic
materials, such as rayon, cotton, hemp, cannabis, wood pulp, creped cellulose
wadding, tissue
wraps and laminates, peat moss, and chemically stiffened, modified, or cross-
linked cellulosic
fibers; synthetic materials, such as polyester fibers, polyolefin fibers,
absorbent foams, e.g., a
flexible resilient polyurethane foam, absorbent sponges, super-absorbent
polymers, absorbent
gelling materials, formed fibers, such as capillary channel fibers and multi
limbed fibers, synthetic
fibers, or any equivalent material or combinations of materials, or mixtures
of these. Preferably
the pledget is made of 100% organic cotton.
The pledget may be formed in any known conventional shape. Preferably the
pledget has
a rounded or tapered insertion tip and a substantially flat end or base
opposite the insertion tip.
The pledget may have a smooth outer surface or it may have a plurality of
grooves or recesses.
The grooves or recesses may be continuous or discontinuous and run in any
direction or pattern on
the outer surface of the pledget. For example, the pledget may employ a
plurality of continuous
grooves that run longitudinally from the insertion tip to the base of the
pledget or a plurality of
continuous groves that run in a spiral pattern from the insertion tip to the
base.
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Representative examples of pledget that may be employed in the present
invention can be
found in U.S. Patent Nos. 8,864,732; 8,777,916; 6,310,269 and 5,911,712 which
are incorporated
herein by reference.
The pledget should also comprise a withdrawal string or thread. The withdrawal
string
may be formed of any materials commonly known in the art, but is preferably
formed from 100%
organic cotton.
Referring now to the drawings, Figures 1 A to lE depict one embodiment of the
present
invention wherein the plunger is segmented with a portion of the plunger
external to the outer
barrel prior to use. More specifically, Figure 1 A shows the three primary
components of the
segmented plunger embodiment which comprise the outer barrel 100, pledget 300,
and segmented
plunger 150. The outer barrel 100 comprises an insertion tip 110, a gripping
region 120 that is
opposite the insertion tip 110, a main body region 130 located between the
insertion tip 110 and
gripping region 120, and an inner cavity that encases the pledget 300 and a
portion of the
segmented plunger 150.
As shown in Figures 1A-1C, the insertion tip 110 may be domed or hemispherical
in shape
or it may be tapered or bullet shape to allow easier and more comfortable
insertion into the vaginal
cavity during use. The domed and tapered shapes are well known in the art and
described in detail
in numerous references such as U.S. Patent Nos. 3,895,634; 6,432,075 and
6,773,422 which are
incorporated herein by reference. The insertion tip 110 comprises a plurality
of petals 112 that are
formed into the insertion tip and separated by a plurality of cuts, slits, or
spacings 114. The petals
112 may be sized and shaped to provide protection to the pledget 300 prior to
use and during
insertion, i.e., use of the tampon applicator, into the vaginal cavity. The
petals 112 may also be
sized and shaped to protect the user from the rough surfaces of the pledget
300 during insertion.
Embodiments of the present invention may comprise 3 to 8 petals, preferably 4
to 6 petals. The
dimensions of the petals 112 are also known in the art and described in
numerous references such
as U.S. Patent Nos. 3,895,634; 6,432,075 and 6,773,422 which are incorporated
herein by
reference. In certain embodiments, the petals 112 form the dome or tapered
shape of the insertion
tip 110 and the dome or tapered shape is preferably formed during the
manufacture of the outer
barrel 100. In one embodiment the dome or tapered shape of the insertion tip
110 is formed during
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the injection molding of the outer barrel 100 and before the pledget 300 is
loaded into the outer
barrel 100. Alternatively, the dome or tapered shape of the insertion tip 110
can be formed after
initial forming of the outer barrel 100 and after the pledget 300 has been
loaded into the outer
barrel 100. The preforming of the dome or tapered shape of the insertion tip
110 during the
manufacture of the outer barrel 100 and/or before the insertion of the pledget
300 into the outer
barrel is the preferred method because it allows for a simpler manufacturing.
The gripping region 120 is located on the outer surface of the outer barrel
100 and opposite
the insertion tip 110. The gripping region 120 is an area of the outer barrel
100 which will allow
the user to grip or hold the tampon applicator during use. The gripping region
120 may comprise
one or more structures to improve the user's hold on the outer barrel 100.
Many of the grip-
improving structures are known in the art and may include one or more
indentations into the outer
barrel 100, one or more raised projections from the outer barrel 100, varying
surface roughness or
textures compared to the main body 130 and insertion tip 110, or a combination
thereof. If
indentations or projections are employed in the gripping region 120, they may
be continuous
around the gripping region 120 or discontinuous. In one embodiment, the
gripping region 120
comprises at least one, preferably at least two, raised projection 122 that
extends outwardly from
the outer surface of the outer barrel 100 and defines the gripping region 120
of the outer barrel.
At least one of the raised projections 122a should be placed on the outer
surface of the outer barrel
100 between the insertion tip 110 and the terminal end of the outer barrel 100
that is opposite the
insertion tip 110 and preferably at a distance from the terminal end of the
outer barrel 100 that is
sufficient to accommodate the user's fingertip, preferably the middle and/or
thumb fingertip. In
certain embodiments, the distance from one of the raised projections 122a to
the terminal end of
the outer barrel 100 is about 10 to 25 mm. In another embodiment, a second
raised projection
122b may be employed at or near the terminal end of the outer barrel 100 that
is opposite the
insertion tip 110. In this embodiment, first raised projection 122a and the
second raised projection
122b define the gripping region 120. As shown in Figure lA to Figure 1C the
raised projections
122a and 122b extend outwardly from the outer barrel 100 in a continuous and
uniform plane. In
an alternative embodiment, the first raised projection 122a may be a
continuous undulating or
sinusoidal projection wherein the peaks and troughs of the projection in
relation to the second
raised projection 122b aid the user to grip the tampon applicator in the
correct location for use. For
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example, the area between the high peak of the sinusoidal projection 122a and
the second
projection 122b will define an area that can accommodate a user's fingertip
while the area between
the trough of the sinusoidal projection 122a and the second projection 122b
will define an area that
cannot accommodate a user's fingertip. This pattern will thereby aid the user
in properly gripping
the tampon applicator.
In some embodiments, the terminal end of the outer barrel 100 that is opposite
the insertion
tip 110 and/or the raised lower projection 122b is flat or planar.
Alternatively, the terminal end of
the outer barrel 100 that is opposite the insertion tip 110 and/or the raised
lower projection 122b
is a concave shape, i.e., curving inwardly or upwardly toward the insertion
tip 110. This concave
shape may also aid the user in correctly orienting their fingers in the
gripping region 120.
The pledget 300 comprises an insertion tip 310 and a base 320 that is opposite
the insertion
tip 310. The insertion tip 310 may be domed or tapered in a shape similar to
the shape of the
insertion tip 110 of the outer barrel. In some embodiments, the insertion tip
310 of the pledget is
similar to the shape of the insertion tip 110 of the outer barrel 100. In this
embodiment, prior to
and/or during use of the tampon applicator, a portion of the petals 112 of the
insertion tip 110 will
be in contact with and supported by the insertion tip 310 of pledget 300. The
pledget 300 also has
a removal string 340 that will extend from the pledget 300, preferably the
base 320 of pledget 300,
and extend through a passageway, opening, channel or cavity of segmented
plunger 150 and/or the
inner cavity of outer barrel 100. The pledget 300 is stored in the inner
cavity of the outer barrel
100 and is preferably loaded into the inner cavity from the terminal end of
the outer barrel 100 that
is opposite the insertion tip 110. The loading of the pledget 300, preferably
after the dome or
tapered shape of the insertion tip 110 has been created, may occur prior to or
concurrently with the
addition of the plunger to the outer barrel 100. The loading of the pledget
300 through the terminal
end or gripping region of the outer barrel 100 with a preformed domed or
tapered insertion tip
shape also allows the inner surface of the outer barrel 100 to be formed
without the need for
retaining and/or support structures such as barbs or hooks in the insertion
tip region of the outer
barrel.
The segmented plunger 150 is a foldable or segmented plunger comprising a
first plunger
portion 152 that will be fully or partially located inside the outer barrel
100, i.e., within the inner
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cavity of the outer barrel 100, near the gripping region 120 and a second
plunger portion 156. The
first plunger portion 152 should be sized and shaped to allow the segmented
plunger 150 to
telescopically move within the inner cavity of the outer barrel 100.
Alternatively, the first plunger
portion 152 should be sized to slidably fit within the inner cavity of the
outer barrel 100. In certain
embodiments the first plunger portion 152 is cylindrical, semi-, hemi-, or
partially cylindrical with
a maximum diameter that is less than the diameter of the inner cavity of the
outer barrel 100.
The segmented plunger 150 may also comprise one or more hinges 154 that will
allow the
first plunger portion 152 and the second plunger portion 156 to be formed in a
single mold piece
and subsequently configured to form the segmented plunger 150 that may be
slidably located
within the inner cavity of the outer barrel 100 and used to push the pledget
300 through the
insertion tip 110 of the outer barrel 100. Alternatively, the segmented
plunger 150 may be formed
in two or more mold pieces such as formation of a first plunger portion 152
and formation of
second plunger portion 156 which are connected via a hinge to form the
segmented plunger 150.
The individual mold pieces may be assembled prior to loading of the segmented
plunger 150 into
the outer barrel 100 or assembled during the loading of the segmented plunger
150 into the outer
barrel 100. The one or more hinges 154 may be formed by any means commonly
known in the art.
For example the hinge may be formed during injection molding of the segmented
plunger 150 by
creating a region where the material used to form the segmented plunger 150 is
thinner than the
surrounding material. This type of hinge is sometimes referred to as a "living
hinge" in the art.
The segmented plunger 150 will also comprise a passageway, opening, channel or
cavity
153 that will allow the removal string 340 of pledget 300 to pass through the
segmented plunger
150 and the inner cavity of the outer barrel 100. Typically the passageway,
opening, channel or
cavity 153 will be formed in the first plunger portion 152 as will be
described in greater detail
below.
The segmented plunger 150 should also comprise the second plunger portion 156
that will
be movably attached to the first plunger portion 152, preferably by a hinge
and most preferably by
a living hinge. The second plunger portion 156 will be outside the inner
cavity of the outer barrel
100 prior to use of the tampon applicator and preferably mated, i.e.,
removably attached or clipped,
to the outer barrel 100 as shown in Figure 1B. The second plunger portion 156
should be sized
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and shaped to allow it to telescopically move or slide within the inner cavity
of the outer barrel
100. In certain embodiments the second plunger portion 156 will be a hollow
hemi-cylindrical or
substantially hemi-cylindrical shape to allow the second plunger portion 156
to conform, mate or
nest to the outer surface of the outer barrel 100 when the applicator is in a
storage mode but also
allow the second plunger portion 156 to slidably move into the inner cavity of
the outer barrel 100
when the segmented plunger 150 in the use mode.
In one embodiment, the segmented plunger 150 will further comprise a locking
portion
158. The locking portion 158 of the segmented plunger 150 will aid in
orienting the first plunger
portion 152 and the second plunger portion 156 into the correct or optimal
positioning during the
use mode as shown in Figure 1E. For example the locking portion 158 of the
segmented plunger
150 may prevent the second plunger portion 156 from moving past the desired
longitudinal axis
that would allow the segmented plunger 150 to easily slide into the inner
cavity of outer barrel 100
and thereby push the pledget 300 from the insertion tip 110. The locking
portion 158 may also
provide additional rigidity and strength to the segmented plunger 150 which
will again aid in easily
sliding the segmented plunger 150 into the inner cavity of the outer barrel
100. The locking portion
158 may extend from the base of the first plunger portion 152, which is
opposite the end of the
first plunger portion 152 that will contact the base of the pledget 300. The
locking portion 158
should also extend from the first plunger portion 152 beyond the terminal end
of the outer barrel
100 that is opposite the insertion tip 110. In certain embodiments, the
locking portion 158 is shaped
to receive and/or mate with a portion of the outer surface of the second
plunger portion 156.
Prior to use of the tampon applicator, a grip region 157 of the second plunger
portion 156
is moved away from the insertion tip 110 in an arching or radial manner to a
position that creates
a continuous longitudinal axis between the first plunger portion 152 and the
second plunger portion
156 as shown in Figures 1C and 1E. In certain embodiments, when the second
plunger portion
156 is moved into the continuous longitudinal axis position, it will engage
with the locking portion
158. In certain embodiments the engagement of the locking portion 158 and the
second plunger
portion 156 will comprise a snap, compression or friction interaction that
will secure the segments
of the segmented plunger 150 into a uniform and unitary structure. Once the
second plunger
portion 156 is engaged with the locking portion 158, the first plunger portion
152, the second
plunger portion 156, and the locking portion 158 will form the segmented
plunger 150 which
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should have sufficient rigidity and orientation with respect to the outer
barrel 100 to allow the user
to exert pressure on the grip region 157 of the segmented plunger 150 towards
the insertion tip 110
of the outer barrel 100 and slide pledget 300 into contact with the petals 112
of the insertion tip
110 and push pledget 300 through the insertion tip 110 of the outer barrel 100
as shown in Figure
1E.
The first plunger portion 152 may be made in a single or unitary piece or it
may be made
in multiple sections or portions that may be combined during assembly of the
applicator or prior
to assembly of the applicator.
As shown in Figure 1F the first plunger portion 152 may comprise a first 252
and a second
352 lateral portion. The first 252 and second 352 lateral portions of the
first plunger portion 152
may be made in a single or unitary piece, preferably with the locking portion
158 and second
plunger portion 156. Alternatively, the first 252 and second 352 lateral
portions of the first plunger
portion 152 may be formed in separate and distinct pieces. The first 252 and
second 352 lateral
portions of the first plunger portion 152 may be joined together prior to
insertion into the outer
barrel 100. If the first 252 and second 352 lateral portions of the first
plunger portion 152 are
formed separately, they may be joined by any means known in the art such as
adhesives, ultrasonic
welding, melt adhesion, physical attachments means such as snaps, friction
mating, compression
mating, hooks, clips, bands, pins or any combination of the foregoing.
Alternatively, the first 252
and second 352 lateral portions of the first plunger portion 152 may be formed
in a single or unitary
structure such as by injection molding. If the first 252 and second 352
lateral portions of the first
plunger portion 152 are formed as a single or unitary structure, the first 252
and second 352 lateral
portions of the first plunger portion 152 may be connected by a living hinge
652 that allows the
first lateral portion 252 and second lateral portion 352 to be folded along a
lateral arc or path and
form the first plunger portion 152. After folding along the lateral arc, the
first 252 and second 352
lateral portions of the first plunger portion 152 may be joined by any means
known in the art such
as adhesives, ultrasonic welding, melt adhesion, physical attachments means
such as snaps, friction
mating, compression mating, hooks, clips, bands, pins or any combination of
the foregoing. As
shown in Figure 1F, the first 252 and second 352 lateral portions may be
joined to form the first
plunger portion 152 by a clip 800 located on the outer surface of the first
lateral portion 252 that
will interact with a locking projection 810 on the outer surface of the second
lateral portion 352.
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The clip 800 may alternatively be located on the outer surface of the second
lateral portion 352
and the locking projection 810 may be located on the outer surface of the
first lateral portion 252.
As shown in Figure 1G the first plunger portion 152 may comprise a first 452
and a second
552 vertical portion. The first 452 and second 552 vertical portions of the
first plunger portion
152 may be made in a single or unitary piece, preferably with the locking
portion 158 and second
plunger portion 156. Alternatively, the first 452 and second 552 vertical
portions of the first
plunger portion 152 may be formed in separate and distinct pieces. The first
452 and second 552
vertical portions of the first plunger portion 152 may be joined together
prior to insertion into the
outer barrel 100. If the first 452 and second 552 vertical portions of the
first plunger portion 152
are formed separately, they may be joined by any means known in the art such
as adhesives,
ultrasonic welding, melt adhesion, physical attachments means such as snaps,
friction mating,
compression mating, hooks, clips, bands, pins or any combination of the
foregoing. Alternatively
the first 452 and second 552 vertical portions of the first plunger portion
152 may be formed in a
single or unitary structure such as by injection molding. If the first 452 and
second 552 vertical
portions of the first plunger portion 152 are formed as a single or unitary
structure, the first 452
and second 452 vertical portions of the first plunger portion 152 may be on
connected by a living
hinge 752 that allows the first vertical portion 452 and second vertical
portion 352 to be folded
along a vertical arc or path and form the first plunger portion 152. After
folding along the vertical
arc, the first 452 and second 552 vertical portions of the first plunger
portion 152 may be joined
by any means known in the art such as adhesives, ultrasonic welding, melt
adhesion, physical
attachments means such as snaps, friction mating, compression mating, hooks,
clips, bands, pins
or any combination of the foregoing.
The first plunger portion 152 should contain a passageway 153 that will allow
the passage
of the removal string 340 through the first plunger portion 152 and through
the outer barrel 100.
In certain embodiments, the passageway 153 may be located in the first 252
and/or second 352
lateral portions or in the first 452 and/or second 552 vertical portions.
Alternatively, the
passageway 153 may be a tract, channel, groove or indentation on the outer
surface of the first
plunger portion 152 that will allow the removal string 340 to pass through the
first plunger portion
152 and through the outer barrel 100 while also allowing the segmented plunger
150 to move freely
within the inner cavity of the outer barrel 100. In certain embodiments, the
removal string 340
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passes through the first plunger portion 152 and is located on the inner
surface 156a of the second
plunger portion 156 as shown in Figure 1C and 1E, especially when the plunger
is in a stored mode
and a use mode. In certain embodiments the passageway 153 in the first plunger
portion 152 is
angled, tapered, sloped or conical so that the opening 153a closest to the
base of the pledget 320
is wider or larger than the opening 153b that is closest to the second plunger
portion 156. This
angle, taper, slope or conical shape of passageway 153 from 153a to 153b aids
in directing the
removal string 340 toward the inner surface 156a of the second plunger portion
156.
Referring now to Figures 2A to 2H and 3A to 3C which depict second embodiments
of the
present invention wherein the plunger is nested within the outer barrel prior
to use. Figure 2A
shows the three primary components of the nested plunger embodiment of the
present invention
which comprises the outer barrel 200, pledget 300 and nested plunger 250. The
outer barrel 200
comprises an insertion tip 210, a gripping region 220 that is opposite the
insertion tip 210, a main
body region 230 located between the insertion tip 210 and gripping region 220,
an inner cavity
that encases the pledget 300 and a substantial portion of the plunger 250.
The insertion tip 210 may be domed or hemispherical in shape or it may be
tapered or bullet
shape to allow easier and more comfortable insertion into the vaginal cavity
during use as
previously described. The insertion tip 210 comprises a plurality of petals
212 that are formed
into the insertion tip and separated by a plurality of cuts, slits, or
spacings 214. The petals 212
may be sized and shaped to provide protection to pledget 300 prior to and/or
during insertion of
the tampon applicator into the vaginal cavity for subsequent expulsion of
pledget 300 into the
vaginal cavity. The petals 212 may also be sized and shaped to protect the
user from the rough
surface of the pledget 300 during insertion. Embodiments of the present
invention may comprise
3 to 8 petals, preferably 4 to 6 petals, and the dimensions of the petals are
also previously described.
In certain embodiments, the petals 212 are formed into the dome or tapered
shape of the insertion
tip 210 during the manufacture of the outer barrel 200 preferably during the
injection molding of
the outer barrel 200 and before pledget 300 is loaded into outer barrel 200.
Alternatively, the dome
or tapered shape of the insertion tip can be formed after initially forming
outer barrel 200 and after
pledget 300 has been loaded into the outer barrel 200. The performing of the
dome or tapered shape
of the insertion tip 210 during the manufacture of the outer barrel 200 and/or
before the insertion
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of the pledget 300 into the outer barrel 200 is the preferred method because
it allows for simpler
manufacturing, i.e., less processing steps.
The gripping region 220 is located on the outer surface of the outer barrel
200 and opposite
the insertion tip 210. The gripping region 220 is an area of the outer barrel
200 which will allow
the user to grip or hold the tampon applicator during use. The gripping region
220 may comprise
one or more structures to improve the users hold on the outer barrel 200 such
as those previously
described for the segment plunger embodiment. In one embodiment, the gripping
region 220
comprises at least one, preferably at least two raised projections 222 that
extend outwardly from
the outer surface of the outer barrel 200 and define the gripping region 220
of the outer barrel 200.
At least one of the raised projections 222a should be placed on the outer
surface of the outer barrel
200 between the insertion tip 210 and the terminal end of the outer barrel 200
that is opposite the
insertion tip 210 and preferably at a distance from the terminal end of the
outer barrel 200 that is
sufficient to accommodate a fingertip as previously described. In one
embodiment, a second raised
projection 222b may be employed at or near the terminal end of the outer
barrel 200 that is opposite
the insertion tip 210. In this embodiment first raised projection 222a and the
second raised
projection 222b define the gripping region 220. As shown in Figure 2A to
Figure 2D the raised
projections 222a and 222b extend outwardly from the outer barrel 200 in a
continuous and uniform
plane. In an alternative embodiment, as shown in Figure 3A to 3C, the first
raised projection 222a
may be a continuous undulating or sinusoidal projection as previously
described. In some
embodiments, the terminal end of the outer barrel 200 that is opposite the
insertion tip 210 and/or
the raised lower projection 222b are a concave shape, i.e., curving inwardly
toward the insertion
tip 210 as previously described.
Attached to the terminal end of the outer barrel 200 that is opposite the
insertion tip 210
and/or the raised lower projection 222b, is a retaining arm 225. When the
tampon applicator is in
an unassembled state, i.e., before the pledget 300 and plunger 250 are
inserted into the inner cavity
of the outer barrel 200, the retaining arm 225 extends from the terminal end
of the outer barrel 200
that is opposite the insertion tip 210 and/or the raised lower projection 222b
and is attached to the
terminal end of the outer barrel 200 that is opposite the insertion tip 210
and/or the raised lower
projection 222b by a hinge 225a, preferably a living hinge as described
previously for the
segmented plunger. The retaining arm 225 also comprises a holding and guiding
projection 225b.
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In the assembled state, i.e., when the pledget 300 and plunger 250 are
inserted into the inner cavity
of the outer barrel 200, as shown on Figures 2B, 2C and 2D, the retaining arm
225 is located in
the inner cavity of the outer barrel 200.
The pledget 300 is similar to the pledget described previously and comprises
an insertion
tip 310, a base 320 that is opposite the insertion tip 310 and a removal
device or string 340. The
pledget 300 is stored in the inner cavity of the outer barrel 200 and the
inner cavity of the plunger
250 which will be described in greater detail below. In certain embodiments
the pledget 300 is
loaded into the inner cavity from the terminal end of the outer barrel 200
opposite the insertion tip
210. The loading of the pledget 300 preferably after the dome or tapered shape
of the insertion tip
210 has been created and may occur prior to the loading of the plunger 250
into the outer barrel
200, concurrently with the loading of the plunger 250 into the outer barrel
200 or after the loading
of the plunger 250 into the outer barrel 200. The loading of the pledget 300
through the terminal
end of the outer barrel 200 with a preformed domed or tapered insertion tip
shape also allows the
inner surface of the outer barrel 200 to be formed without the need for
retaining and/or support
structures such as barbs or hooks in the insertion tip region of the outer
barrel 200.
The plunger 250 comprises an insertion end 255, a push end 254, a body portion
256
located between the insertion end 255 and push end 254, a guide track or
opening 258 and an inner
cavity that extends longitudinally through the plunger 250. The plunger 250
has a size and
dimension that allow it to slide along the longitudinal axis of the inner
cavity of the outer barrel
200. As shown in Figure 2H, the plunger 250 contains one or more retaining
projections 262 that
extend inwardly from the wall of the plunger 250 into the inner cavity of the
plunger 250. The
one or more retaining projections 262 are located near the insertion end 255
of the plunger 250.
As also shown in Figure 2H, when this embodiment of the present invention is
assembled, retaining
arm 225 is positioned in the inner cavity of the outer barrel 200 and the
holding and guiding
projection 225b of retaining arm 225 extends inwardly towards the inner cavity
of the outer barrel
200 and the inner cavity of the plunger 250. The holding and guiding
projection 225b will engage
the guide track or opening 258 of plunger 250 and will guide the longitudinal
movement of the
plunger 250 within the inner cavity of the outer barrel 200. The holding and
guiding projection
225b will also engage the base 320 of pledget 300 and prevent the movement of
pledget 300 away
CA 3060562 2019-10-29
from the insertion tip 210 of the outer barrel 200 when the nested plunger is
moved from a
compacted position to a ready to use position.
In one embodiment, when the nesting plunger embodiment is assembled, the
plunger 250
with or without the pledget 300 is inserted into the terminal end of the outer
barrel 200 opposite
the insertion tip 210 and oriented so that the holding and guiding projection
225b engages the
guide track or opening 258 of plunger 250. The plunger 250 is pushed into the
outer barrel 200
until the insertion end 255 of plunger 250 engages the base of the petals 212
and/or the base of the
openings 214 to create a nested or compacted position for the tampon
applicator. The retaining
arm 225 is moved into the inner cavity of the outer barrel 200 before or
during the insertion of the
plunger 250. Once the plunger 250 is in the nested or compacted position, the
insertion tip 310 of
pledget 300 is inserted into the push end 254 of plunger 250 and moved
longitudinally through the
inner cavity of plunger 250 until the insertion tip 310 of pledget 300 extends
from the insertion
end 255 of plunger 250 and preferably, but not necessarily, contacts petals
212 of the insertion tip
210 of outer barrel 200. The insertion tip 310 of pledget 300 may also be in
contact with the petals
212 when the plunger is in the nested or compacted position. In certain
embodiments, the plunger
250 may be inserted into the outer barrel 200 with the pledget 300. In this
embodiment, the pledget
300 is inserted into the push end 254 of plunger 250, preferably, but not
necessarily, with the
insertion tip 310 of pledget 300 extending from the insertion end 255 of
plunger 250, and the
removal string 340 extending longitudinally from the base 320 of pledget 300
through the inner
cavity of plunger 250 and extending rearwardly through the push end 254 of
plunger 250.
When using the nesting plunger embodiment, the user will pull the push end 254
of plunger
250 longitudinally away from the insertion tip 210 of outer barrel 200 until
the holding and guiding
projection 225b engages the stop end 258a of guide track or opening 258 of
plunger 250. The
holding and guiding projection 225b will also be in contact with the base 320
of pledget 300 while
the user pulls the plunger 250 rearwardly from outer barrel 200. The
engagement of the holding
and guiding projection 225b with the base 320 of pledget 300 will prevent the
pledget 300 from
moving rearwardly with the plunger 250 during the ready to use phase and help
to maintain the
insertion tip 310 of pledget 300 in contact with or in close proximity to the
petals 212 of the
insertion tip 210 of outer barrel 200. Once the plunger 250 has been pulled
rearwardly so the
holding and guiding projection 225b engages the stop end 258a of guide track
or opening 258 and
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stops the rearward movement, the retaining projections 262 that depend
inwardly into the inner
cavity of plunger 250 should engage the base 320 of pledget 300. Once the
plunger 250 has been
pulled rearwardly and the retaining projections 262 engage the base 320 of
pledget 300, the nesting
plunger embodiment is in the loaded or ready to use position as shown in
Figure 2E and 3B. From
the loaded or ready to use position the user will hold the gripping region 220
of outer barrel 200
and exert pressure on the push end 254 of plunger 250 towards the insertion
tip 210 of the outer
barrel 200 and thereby slide pledget 300 through the insertion tip 210 of the
outer barrel 200 as
shown in Figure 2F and 3C.
In certain embodiments the holding and guiding projection 225b and the
retaining
projections 262 may be any shape or size that will allow the pledget 300 to be
loaded into the
tampon applicator without substantially damaging the pledget 300 but will also
provide sufficient
contact with the base 320 of pledget 300. In some embodiments, as shown in
Figure 2H, a cross
sectional shape of holding and guiding projection 225b and a cross sectional
shape of retaining
projections 262 may be triangular or substantially triangular, wherein one leg
of the triangle is
parallel or substantially parallel with the longitudinal axis of the outer
barrel 200 and/or the plunger
250, one leg or base of the triangle is perpendicular or substantially
perpendicular to the
longitudinal axis of the outer barrel 200 and plunger 250, and one leg of the
triangle extends
outwardly from the push end 254 of the plunger toward the insertion tip 255 of
the plunger 250.
Typical dimensions for each of the outer barrel and plunger includes a length
of from about
50 to about 100 millimeters, a diameter of from about 8 to about 16
millimeters, and a thickness
of from about 0.4 to about 0.6 millimeters. Preferably, the diameter of the
plunger is less than the
diameter of the inner cavity of the outer barrel to allow for a telescopic
arrangement of the two.
Typical dimensions and arrangement of the petals are known in the art and
described in numerous
references such as U.S. Patent Nos. U.S. Patent Nos. 3,895,634; 6,432,075 and
6,773,422 which
are incorporated herein by reference.
In addition to the benefits already noted for the above embodiments, the
present invention
will also exhibit the following improvements and benefits:
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= In the final ejection position, the gripping or push region of the
plunger is at a greater
distance from the grip region of the barrel, thereby avoiding gripping the
applicator too
tightly between the index finger, middle finger and thumb which can lead to
difficulty in
pushing the plunger, incomplete ejection of the pledget from the applicator
and resulting
in less chance of pinching the labia between the outer barrel and the plunger;
= No need for barbs or projections at the tip of the inner cavity of the
outer barrel which
can interfere with plunger movement and pledget ejection and further allows
for an easier
manufacturing; and
= The insertion tip of the plunger stops at the base of the petals to
ensure proper release to
the pledget.
The invention illustratively described herein suitably may be practiced in the
absence of
any element or elements, limitation or limitations which is not specifically
disclosed herein. Thus,
for example, in each instance herein, any of the terms "comprising,"
"consisting essentially of"
and "consisting of" may be replaced with either of the other two terms. The
terms and expressions
which have been employed are used as terms of description and not of
limitation, and there is no
intention in the use of such terms and expressions of excluding any
equivalents of the features
shown and described or portions thereof, but it is recognized that various
modifications are
possible within the scope of the invention claimed. Thus, it should be
understood that although
the present invention has been specifically disclosed by preferred embodiments
and optional
features, modification and variation of the concepts herein disclosed may be
resorted to by those
skilled in the art, and that such modifications and variations are considered
to be within the scope
of this invention as defined by the appended claims.
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