Tampons, applicators and their manufacturing methods

Abstract

The tampon pledget has a unique forming process that allows for reduced material (weight) and optionally increased absorbency without reducing gram per gram absorbency. The tampon pledget is formed by a unique carding, cross wrapping, and needle punching process. The tampon applicator is formed having one or more components from sustainable and / or compostable materials. The tampon applicator plunger has at least one modified end. The tampon applicator plunger has improved strength. The tampon assembly has improved retention.

Description

[Technical field]

[0001] (Related Applications) This application claims priority to U.S. Provisional Patent Application No. 63 / 151,258, filed February 19, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] (Technical field) The present disclosure relates to tampon pledgets and tampon applicators that function individually and together as a tampon applicator assembly. [Background technology]

[0003] Tampon pledgets provide an absorbent material for storing menstrual fluid. The absorbent material includes cotton and rayon fibers, with rayon fibers historically having a greater absorbent capacity, i.e., the ability to hold more liquid than cotton fibers. Rayon fibers are processed and, in the eyes of some consumers, their chemical composition creates concerns. Thus, there is a need for cotton tampon pledgets that perform similarly to rayon tampon pledgets. Thus, there is a need to reduce the amount of rayon fiber used by creating improved methods for the manufacture and formation of tampon pledgets that maintain or increase absorbency.

[0004] Tampon applicators have traditionally been made from plastic or cardboard. Plastic applicators are perceived by some consumers as providing improved comfort, and thus the majority of consumers of tampon applicator products utilize plastic applicators. Nevertheless, as the world becomes more aware of and eager to mitigate the harm caused by non-sustainable, non-recyclable, non-biodegradable and non-compostable products, there is an increased need for better performing natural-based applicators and more environmentally friendly applicators in general. Summary of the Invention [Means for solving the problem]

[0005] In one aspect of the present invention, a tampon pledget is provided. The tampon pledget comprises absorbent fibers such as rayon or cotton or a combination thereof. The tampon pledget is composed of a web, loose fibers, or multiple webs stacked together such as, but not limited to, a cross-pad configuration or an offset configuration. The material (absorbent fibers) of the tampon pledget is composed of carded, cross-lapped, and needle-punched materials. The absorbent fibers are needle punched so that there are 5 or more needles per square centimeter of absorbent material, or 20 or more needles per square centimeter, or 30 or more needles per square centimeter, or 40 or more needles per square centimeter, or 70 or more needles per square centimeter, or up to 150 needles per square centimeter, or between about 5 needles per square centimeter and about 150 needles per square centimeter, or between about 40 needles per square centimeter and about 140 needles per square centimeter, or between about 70 needles per square centimeter and about 130 needles per square centimeter, or between about 80 needles per square centimeter and 120 needles per square centimeter, or between about 30 needles per square centimeter and about 90 needles per square centimeter, or about 40 needles per square centimeter, or about 80 needles per square centimeter. The tampon pledget is then formed by compressing the absorbent material, either by axial compression and / or radial compression, to form a generally cylindrical shape, optionally with a tapered tip, with a string provided at the removal end of the pledget for easier removal by the consumer.

[0006] The tampon pledgets of the present disclosure have a reduced mass relative to existing tampons of a given absorbency zone (e.g., a standard tampon absorbs 6 to 9 grams of fluid, a Super tampon absorbs 9 to 12 grams of fluid, a Super Plus tampon absorbs 12 to 15 grams of fluid, an Ultra tampon absorbs 15 to 18 grams of fluid, and a Lite tampon absorbs up to 6 grams of fluid), but can absorb the same or more fluid as a similarly classified tampon of that absorbency zone. In certain embodiments, the tampon pledgets of the present disclosure can absorb 10% or more, or 15% or more, or 18% or more fluid compared to known tampons in their respective absorbency zones, while including a lower basis weight. In one embodiment of the present disclosure, the tampon pledgets of the present disclosure have a lower density in their respective absorbency zones than currently available tampons. In one embodiment of the present disclosure, a tampon pledget according to the present disclosure includes less mass in each absorbent strip than currently available tampon pledgets.

[0007] In another aspect of the present disclosure, a tampon applicator system is provided. The tampon applicator system includes materials that are compostable, biodegradable, sustainable, natural, recycled, and recyclable. In one embodiment, the applicator barrel is one of the materials described above. In one embodiment, the applicator plunger is one of the materials described above. In one embodiment, the applicator barrel and the applicator plunger are one of the materials described above. In one embodiment, the applicator barrel and the applicator plunger are different materials (but include one of the materials described above).

[0008] In a further aspect of the present disclosure, the tampon applicator system (including the tampon pledget) is made from compostable, biodegradable, sustainable, natural, recycled and recyclable materials. For example, in one embodiment, a cotton tampon pledget is provided (i.e., natural materials), a bioplastic applicator barrel is provided (i.e., natural materials), and a cardboard plunger is provided (i.e., compostable materials). In other embodiments, recycled plastic materials are used in either or both of the applicator system, applicator barrel, or applicator plunger.

[0009] In a further aspect of the disclosure, an insertion end of a plunger is provided. The plunger is generally cylindrical having an insertion end, a consumer end substantially opposite the insertion end, and an intermediate portion separating and connecting the insertion end and the consumer end. The insertion end has a modified end forming at least three vertices at the end of the plunger. The modified plunger end has up to ten vertices. The modified plunger end is polygonal, such as triangular, square, pentagonal, hexagonal, heptagonal, octagonal, nonagonal, decagonal, etc. The diameter of the polygon is between about 9.25 mm and about 10.25 mm, more preferably 9.5 mm to about 10 mm, or about 9.75 mm.

[0010] The tampon applicator assembly has additional preferred features. For example, the tampon applicator assembly has improved ejection force (i.e., the force that a user must apply to the consumer end of the plunger to push the plunger inwardly within the applicator barrel, thereby pushing the withdrawal end of the pledget so that the insertion end of the plunger passes through the insertion end of the applicator barrel, allowing the pledget to be expelled from the applicator barrel by full stroke movement of the plunger). For example, the plunger has improved column strength. For example, the plunger with the modified insertion end has improved retention force over prior art plungers.

[0011] Some tampons are available in a format that includes an applicator that facilitates insertion of the tampon. There are a variety of different types of tampon applicators available. For example, some types of applicators include a barrel portion and a plunger. Prior to use, the tampon is placed within an interior cavity of the barrel. The plunger is operable to move relative to the barrel to expel the tampon during insertion. The plunger is inserted into the applicator barrel and then the end of the plunger is shaped. In embodiments having a miniature plunger that includes two portions, an inner plunger and an outer plunger, the inner plunger is attached to the outer plunger before being inserted into the tampon applicator barrel. The tampon is then inserted from the insertion end.

[0012] The above-described aspects of the present invention include specific manufacturing and assembly aspects further contemplated herein, including specific apparatus for constructing the disclosed aspects.

[0013] The present method and its associated advantages will become more readily apparent upon consideration of the detailed description provided below, including the accompanying drawings. [Brief description of the drawings]

[0014] [Figure 1] 1 is a cross-sectional photograph of multilobal rayon fiber. [Diagram 2] 1 is a cross-sectional photograph of a single-row rayon fiber. [Diagram 3] This is a cross-sectional photograph of a cotton fiber. [Figure 4] 1 is a photograph of a tampon according to the present disclosure. [Diagram 5] FIG. 1 shows tampon pledget absorbency data for cotton and multilobal rayon fibers. [Figure 6] FIG. 1 shows gram / gram absorbency data for cotton and multilobal fibers. [Figure 7] 1A-1D are diagrams illustrating process steps for manufacturing a tampon pledget according to the present disclosure. [Figure 8]1A-1D are diagrams illustrating process steps for manufacturing a tampon pledget according to the present disclosure. [Figure 9] 1A-1D are diagrams illustrating process steps for manufacturing a tampon pledget according to the present disclosure. [Figure 10] 1 is a schematic diagram of an exemplary cross pad layup for a tampon pledget according to the present disclosure. [Figure 11] 1 is a schematic diagram of an exemplary tampon pledget forming process according to the present disclosure. [Figure 12] 1 is a process diagram contemplated for a tampon pledget forming process according to the present disclosure. [Figure 13] 1 is a perspective view of an exemplary embodiment of an end of a tampon applicator plunger according to the present disclosure. FIG. [Figure 14] 1 is a perspective view of an exemplary embodiment of an end of a tampon applicator plunger according to the present disclosure. FIG. [Figure 15] 1 is a perspective view of an exemplary embodiment of an end of a tampon applicator plunger according to the present disclosure. FIG. [Figure 16] 1 is a perspective view of an exemplary embodiment of an end of a tampon applicator plunger according to the present disclosure. FIG. [Figure 17] 1 is a perspective view of an exemplary embodiment of an end of a tampon applicator plunger according to the present disclosure. FIG. [Figure 18] 1 is a perspective view of an exemplary embodiment of an end of a tampon applicator plunger according to the present disclosure. FIG. [Figure 19] 1 is a perspective view of an exemplary embodiment of an end of a tampon applicator plunger according to the present disclosure. FIG. [Figure 20] 1 is a photograph of a tampon applicator plunger prior to undergoing a forming process in accordance with the present disclosure; [Figure 21] 1 is a photograph of an exemplary tampon applicator plunger after undergoing a forming process according to the present disclosure. [Figure 22] FIG. 1 is a perspective view of an exemplary forming tool and formed tampon applicator plunger according to the present disclosure; [Diagram 23] FIG. 1 is a perspective top view of an exemplary molding tool according to the present disclosure. [Figure 24] 1 is a side cross-sectional view of an exemplary mold tool according to the present disclosure. [Diagram 25] 1 is a schematic diagram of an exemplary molding tool according to the present disclosure. [Figure 26] 1 is a schematic diagram of an exemplary molding tool according to the present disclosure. [Figure 27] 1 is a schematic diagram of an exemplary tampon applicator forming machine according to the present disclosure. [Figure 28] 1 is a schematic diagram of an exemplary tampon applicator forming machine according to the present disclosure. [Figure 29] 1 is a cross-sectional view of an exemplary tampon applicator assembly according to the present disclosure. [Diagram 30] 1 is a cross-sectional view of an exemplary tampon applicator assembly according to the present disclosure. [Diagram 31] 1 is a cross-sectional view of an exemplary tampon applicator assembly according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] As shown in Figures 1-3, various absorbent fibers are utilized in forming a tampon pledget 10. For simplicity, the terms "pledget," "tampon" 10, and "tampon pledget" 10 may be used interchangeably for purposes of this disclosure and are generally shown in Figure 4. Figures 1-3 show cross-sectional shapes of the fibers obtained from a scanning electron microscope. Figure 1 shows a multi-lobal rayon fiber 12, such as that sold under the trade name GALAXY® by Kelheim. Figure 2 shows a single lobal (or staple) rayon fiber 14, such as that sold by Kelheim or Lenzing. Figure 3 shows a cotton fiber 16, such as that sold by Barnhardt.

[0016] In general, multilobal fibers 12 tend to have the greatest surface area and therefore the greatest absorbency potential. Test data suggests this, including the tables shown in Figures 5 and 6. In fact, Figure 5, entitled "Distribution of Simulated Pledget Absorbency (g) Data" (and designated as reference numeral 18), shows that multilobal rayon fibers 22 have a higher theoretical standard pledget absorbency of about 7.5 g (and between about 6.2 g and about 8.3 g) than cotton fibers 20, which have an absorbency of about 6.0 g (and between about 4.7 g and about 6.7 g). Similarly, FIG. 6, entitled "Distribution of Grams / Gram Absorbency Data" (and designated by reference numeral 26), sets forth the distribution of grams / gram absorbency of the fibers, with the multilobal rayon fibers 12 having an average absorbency of just under 4.0 g / g (range of about 3.3 g / g to about 4.3 g / g), while the cotton fibers 16 have an average absorbency of just under 3.25 g / g (range of about 2.3 g / g to about 3.6 g / g).

[0017] Absorbency data throughout this disclosure has been determined in accordance with FDA requirements, using an experimental setup (syngyna test chamber) in accordance with Figures 1 and 2 of 21 CFR Part 801.432(f)(2). For the absorbency test, an unlubricated condom with a tensile strength between 17 megapascals (MPa) and 30 MPa, measured in accordance with the procedure of ASTM D3492-97 "Standard Specification for Latex Contraceptive Devices (Male Condoms)"1 (incorporated by reference by SC552(a)), is attached to the large end of a glass chamber (or a hard transparent plastic chamber) with a rubber band (see Figure 1) and pushed through the small end of the chamber with a smooth finish rod. The condom is pulled until all slack is removed. The tip of the condom is cut off and the remaining end of the condom is stretched over the end of the tube and secured with a rubber band. A pre-weighed (to the nearest 0.01 gram) tampon is placed inside the condom membrane so that the center of gravity of the tampon is in the center of the chamber. An injection needle (14 gauge) is inserted through the septum created by the tip of the condom until it touches the end of the tampon. The outer chamber is filled with water pumped from a temperature-controlled water bath and maintained at an average temperature of 27 ± 1°C. The water is returned to the water bath as shown in Figure 2. Syngyna fluid (10 grams of sodium chloride, 0.5 grams of Certified Reagent Acid Fushsin, and 1,000 milliliters of distilled water) is then pumped through the injection needle at a rate of 50 milliliters per hour. The test shall end when the tampon is saturated and the first droplet leaves the apparatus. (If liquid is detected through the condom fold before the tampon is saturated, the test result shall be discarded). The water is then drained and the tampon is removed and immediately weighed to the nearest 0.01 g. The absorbency of the tampon is determined by subtracting the dry weight from this value. Condoms should be changed after 10 tests or at the end of the day the condom was used for the tests, whichever occurs first.

[0018] Surprisingly, applicants of the present disclosure have realized a process and resulting tampon pledget 10 that allows for the same or improved pledget absorbency with less fiber and therefore less mass. This is desirable for many reasons, namely, the ability to use less fiber and thus reduce waste and additional impacts on the environment (i.e., energy to manufacture the fiber, energy to transport the fiber, etc.), the ability to use absorbents with fewer or no additives, or the ability to avoid adding additional natural fibers to compensate for lower absorbency potential. If more natural fiber is required to provide the appropriate amount of absorbency, the pledget 10 will be larger or will need to be compressed more to maintain the size of the pledget 10 with more absorbent fiber. Adding more fiber increases costs, and if the size of the pledget 10 cannot be increased, adding more fiber can adversely affect absorption due to excessive densification, leading to the fibers not being able to fully expand to their absorption potential.

[0019] Surprisingly, the gram / gram absorbency of the tampon pledget 10 of the present disclosure is comparable (despite the use of less absorbent fibers) or improved (despite the use of less absorbent fibers or less fibers). The gram / gram absorbency is the maximum volume of fluid that the tampon pledget 10 will absorb divided by the mass of the dry tampon pledget 10 (before absorption).

[0020] In one aspect of the disclosure, the pledget 10 has a mass that is at least 10% less than existing tampon pledgets sold under the PLAYTEX GENTLE GLIDE® brand, or at least 15% less than existing tampon pledgets sold under the PLAYTEX GENTLE GLIDE® brand. In one aspect of the disclosure, the cotton 14 pledget 10 has a mass that is at least 10% less than existing tampon pledgets made from rayon fibers 12, 16, or at least 15% less than existing tampon pledgets made from rayon fibers 12, 16, or at least 16% less than existing tampon pledgets made from rayon fibers 12, 16.

[0021] In one aspect of the disclosure, the pledget 10 has at least 10% greater absorbency than a tampon pledget sold under the Playtech Gentle Glide® brand, or at least 15% greater absorbency, or at least 16% greater absorbency, or at least 18% greater absorbency. In one aspect of the disclosure, the cotton 14 pledget 10 has at least 10% greater absorbency than a pledget 10 made from rayon fibers 12, 16, or at least 15% greater absorbency than a pledget 10 made from rayon fibers 12, 16, or at least 16% greater absorbency than a pledget 10 made from rayon fibers 12, 16.

[0022] The fibers have a fiber diameter of about 7 microns to about 40 microns, or about 25 microns to about 40 microns, or about 30 microns to about 40 microns. The fibers have a fiber length of about 0.9 inches (about 2.3 cm) to about 1.2 inches (about 3 cm), or about 0.90 inches (about 2.3 cm) to about 1.0 inches (2.54 cm).

[0023] The process diagram of FIG. 12 illustrates the unique process of the present disclosure. The fibers are provided in bales and undergo a step of separating the fibers from the bale (this step is referenced by reference numeral 60). The unwound fibers are conveyed to a carding machine where the fibers are aligned so that they are generally parallel (this step is referenced by reference numeral 62). After carding, the aligned fibers are conveyed to a webbing machine where the fibers are cross-wrapped by overlapping the fibrous web on itself (this step is referenced by reference numeral 64). Cross-wrapping is performed such that a layer of the fibrous web is orthogonal to an immediately adjacent layer of the fibrous web. After webbing, the fibrous web is needle punched (this step is referenced by reference numeral 66). During the needle punching step 66, a needle punching die (not shown) imparts from about 40 punches per square centimeter to about 80 punches per square centimeter to the fibrous web. This is in contrast to conventional processes where the fibrous web is imparted with 4 punches per square centimeter.

[0024] In some forming processes, a cross pad pledget configuration 53 is provided as illustrated in FIG. 10. For a cross pad configuration 53 for a tampon 10, at least two pads 52, 54 are used, with at least one upper pad 54 generally vertically placed on top of at least one lower pad 52. The at least one upper pad 54 and at least one lower pad 52 form a cross pad layup (or cross pad configuration) 53. This configuration 53 is generally referred to as "cross" given that the at least one upper pad 54 is generally vertically disposed relative to the at least one lower pad 52, although other configurations are possible, thereby creating additional shapes. Once the cross pad layup 53 is provided, it is compressed about the central overlap region 55 of the at least two pads 52, 54 to generally form a cylindrical shape 40. An oven tube 50 and rams 47, 48 are then used to provide the appropriate shape and configuration. Additional shaping of the insertion end can be accomplished by utilizing a ram 47 that includes a dome former 47a, and it may be further useful to heat such dome former 47a. In an embodiment utilizing a heated dome former 47a, the tool temperature is approximately 380 degrees Fahrenheit. The forming apparatus for the tampon 10 includes two cylinders, the upper cylinder (for the ram 47) exerts a pressure of between about 65 psi and about 80 psi, and the lower cylinder (for the ram 48) exerts a pressure of between about 75 psi and about 90 psi. Current cross-pad configuration pledgets (as they existed prior to the filing of this disclosure) are known in the market under the PLAYTEX® SPORT® and PLAYTEX® GENTLE GLIDE® brands. In another forming process, a single fibrous pad (not shown) is wound into a roll and then compressed into a generally cylindrical pledget 10. In yet another forming process, loose fibers are compressed into the shape of the tampon 10. In any of the forming processes described above, a cover stock (not shown) may be applied and sealed to itself and / or to the pledget 10 by heat, ultrasonics, adhesives, or other known bonding processes.The coverstock (also known as an overwrap) provides additional structure to the pledget 10 and is useful for controlling expansion or liquid absorption or retention.

[0025] The tampon pledget 10 of the present disclosure is formed from a web of material (following the opening step (60), carding step (62), cross wrapping step (64) and punching process steps (66) described further herein) which is cut to form batts or pads of material in a pad cutting process step (68). The batts or pads 52, 54 have a width 56 of between about 1 inch (about 2.5 cm) and 3 inches (about 7.6 cm), or about 2 inches (about 5.1 cm). Depending on the construction of the tampon pledget 10, the cross pad configuration 53 has a longest dimension 58 (i.e., length or width, depending on how it is positioned within the cross pad configuration 53) of between about 3 inches (about 7.6 cm) and 5 inches (about 12.7 cm), or about 4 inches (about 10.2 cm). A tampon pledget 10 having at least one pad is then formed (eg, by a tube oven) via a process step (70) as further described below, via a pad cutting step (68).

[0026] Surprisingly, it has been found that there is an inverse correlation between gram per gram absorbency and density of the pledget 10. The pledgets 10 of the present disclosure, when formed, have a density that is less than the densities currently sold under the Playtech® Gentle-Glide® brand (when compared between pledgets of a particular absorbency range, respectively).

[0027] The pad layup is then compressed, for example, by inserting pads 52 and 54 into a heated oven tube 50 (FIG. 11) and the fibers of pads 52 and 54 are radially compressed laterally or widthwise along axis A to generally form a cylinder 40. In one embodiment, the inside diameter of oven tube 50 is approximately 0.407 inches for a super absorbent tampon 10 and the target heating temperature is 230° F. In one embodiment, the cylindrical structure 40 is radially compressed along axis A within oven tube 50 at the outer periphery 42 of cylindrical structure 40. In accordance with one aspect of the present invention, cylindrical structure 41 (of the not yet fully formed tampon pledget) is then axially compressed within oven tube 50 in a direction along vertical axis B. In one embodiment, pressure is applied to insertion end 44 and bottom end 46 of cylindrical structure 40, causing cylindrical structure 40 to be axially compressed along vertical axis B. In one embodiment, the insertion end 44 is axially compressed with a conical / semi-conical section 47a on a ram 47, and the withdrawal end 46 is axially compressed with a flat shaped ram 48. In one embodiment, the axial compression of the ends 44 and 46 occurs at a temperature of about 385 degrees Fahrenheit for a dwell time of about 12 seconds.

[0028] A further advantageous aspect of the manufacturing process for the tampon pledget 10 of the present disclosure is that no water is required. Avoiding the use of water is useful for improving the performance of the final product since water, when absorbed into the fibers, essentially reduces the absorbent capacity of the fibers.

[0029] As shown in Figures 7-9, the absorbency, grams per gram, of the new sample tampon 10 with a mass of 120 gsm was equal to or less than the mass of the other samples produced with the control process, yet had the highest gram per gram absorbency. To make a more direct comparison, a prototype tampon pledget 10 was made of 100% cotton that was processed with the control process without using water. Even with the removal of water from the control process, the new process resulted in a tampon 10 that exceeded the absorbency of the improved control process tampon 10 by approximately half a gram.

[0030] For clarity, FIG. 7 illustrates an interval plot of absorbency 34 comparing Samples A, B, C, and D by absorbency (g) 36. FIG. 7 shows data at 95% confidence intervals for the reported mean data. Sample A has 100% cotton fiber with a basis weight of 120 gsm formed by the current control process, Sample B has 100% cotton fiber with a basis weight of 120 gsm formed by the new process, Sample C is made with 100% multilobal rayon fiber with a basis weight of 143 gsm formed by the current process, and Sample D has 100% cotton fiber with a basis weight of 145 gsm formed by the current process. FIG. 8 is an interval plot of grams per gram absorbency 38 for Samples B, C, and D as grams per gram absorbency (49). As shown in both plots, the tampons 10 of the present disclosure, exemplified by the samples having 100% cotton fibers with a basis weight of 120 gsm formed by the new process, outperformed the test pledgets made by the current process, even though they had more absorbent fibers and more fibers (due to their higher basis weight).

[0031] To expedite bench testing, the structure of the tampon pledget 10 can be simulated by manually fabricating test pledgets 10 without the webbing step 64. Some samples used cotton fibers 14 as available from Barnhart, Inc., while others used Kelheim Galaxy ML Rayon 16, as further described in Table 1 below. To prepare the samples, the test material (cotton 14 or rayon 12, 16) was removed from the prepackaged bale and manually opened to separate the fibers and remove the effects of bale compression. Approximately 1.88 grams of fiber was weighed and manually pressed into the oven tube of a PLAYTX® SPORT® standard absorbency tampon pledget 10, and then compressed into the shape further defined by the PLAYTX® SPORT® standard absorbency tampon pledget 10 via a ram 47 having a dome former 47a.

[0032] [Table 1]

[0033] FIG. 9, entitled "Grams per Gram Plot" (and designated as reference numeral 28), is another plot showing the grams per gram absorbency 49 of an additional embodiment of the present disclosure. As shown, Sample 1, labeled "Standard Control Gentle Glide® 143 gsm," was the control sample and was the current Gentle Glide® with standard absorbency made from rayon fiber with a basis weight of 143 gsm. Samples 2 through 5 were new samples of the present disclosure and included 100% cotton fiber with basis weights of 120 gsm, 120 gsm, 130 gsm, and 145 gsm, respectively. Samples 2 and 3 were from separate lots. Sample 6, labeled "Super Control Gentle Glide® 217 gsm," was the control sample and was the current Gentle Glide® with super absorbency made from rayon fiber with a basis weight of 217 gsm. Samples 7 through 10 are new samples of the present disclosure and include 100% cotton fibers with basis weights of 160 gsm, 160 gsm, 175 gsm, and 190 gsm, respectively. Sample 11 is a sample of the present disclosure using 100% Galaxy trilobal rayon fibers and has a basis weight of 190 gsm. As shown, the inventive samples outperformed the control samples at the lower basis weights by between about 10 g and about 25 g (for normal absorbency) and between about 30 g and about 60 g (for superabsorbency). In fact, tampons of the present disclosure can have equivalent or superior gram per gram absorbency at a basis weight of at least about 10 gsm to about 25 gsm lower; or at a basis weight of between about 120 gsm to about 145 gsm, or between about 120 gsm to about 140 gsm, or between about 120 gsm to about 130 gsm for standard absorbency tampons, or at a basis weight of between about 160 gsm to about 190 gsm, or between about 160 gsm to about 175 gsm for superabsorbent tampons.

[0034] Extrapolating the data based on the above testing, it is believed that the present disclosure provides the following mass improvements (over Playtech® brand currently available products):

[0035] [Table 2]

[0036] A further aspect of the present disclosure relates to a tampon applicator 120 that includes a tampon applicator plunger 80. For simplicity, the term "plunger" 80 is used interchangeably with "applicator plunger" 80 and also with "tampon applicator plunger" 80. For further simplicity, the term "applicator barrel" 122 refers to the non-plunger 80 portion of the tampon applicator 120. A tampon applicator 120 is provided that uses at least one of compostable materials, sustainable materials, natural materials, recycled materials, and recyclable materials. In some embodiments, the applicator barrel 122 is a sustainable material, a natural material, and / or a compostable material. In some embodiments, the applicator plunger 80 is a sustainable material and / or a compostable material.

[0037] Examples of such materials include bioplastics, starch-based materials, naturally occurring fiber materials, cellulosic materials, bioplastics, paper, paperboard, cardboard, and bygasse products. Sugarcane, corn, potato, rice, seaweed, and mushroom-based materials are examples that may be natural, starch-based, and / or cellulosic.

[0038] In one embodiment, the applicator barrel 122 comprises a natural-based material, which is optionally starch-based or cellulose, or otherwise classified as a bioplastic. In one embodiment, the plunger 80 is a compostable material, such as a paper, paperboard, or cardboard material. Preferably, one or more components of the applicator 120 include materials other than conventional oil-based resins, such as low density polyethylene, polypropylene, and / or polyester.

[0039] 13-31 focus on a unique plunger 80 according to the present disclosure, including a molding apparatus for the unique plunger 80 (FIGS. 22-28), as well as the unique plunger 80 as part of an applicator assembly (FIGS. 29-31). The plunger 80 of the present disclosure has a modified insertion end 78 that facilitates retention of the plunger 80 within the applicator barrel 122 during use. The modified insertion end 78 differs from traditional retention features that use prongs, rings, or flares. In effect, the modified insertion end utilizes a forming die to force the plunger insertion end outward into a shape with at least three vertices 74 that form a circumscribed circle. These vertices 74 form a maximum diameter or dimension of the modified insertion end 78 that is greater than a maximum diameter or dimension 106 of the body portion 104 of the plunger 80.

[0040] A modified plunger end 78 having an apex 74 as described above may be provided at at least one of the insertion end 108 and the consumer end 110. In the latter, when the modified plunger end 112 is at least on the consumer end (or finger end) 110, it provides an enlarged, resilient area for gripping its periphery or as a finger pad for placing fingers on the consumer end 110.

[0041] As illustrated in Figures 13-19, the modified plunger end can be shaped with an even number of vertices 74 or an odd number of vertices. Preferably, there are between 3 and 10 vertices 74. Too few vertices 74 can lead to the plunger 80 not being properly retained within the applicator barrel 122, or the consumer end 110 of the plunger 80 not being large enough or comfortable. Too many vertices 74 can be difficult to mold and effectively result in a relatively continuous flare shape, which can lead to reduced retention. Additionally, it can be advantageous to have an odd number of vertices 74 such that the modified plunger end 78 (and / or 112) is less (or not) symmetrical along its cross section, thereby increasing its resilience in both column strength (or collapse force) and retention (both properties and related tests are described in more detail below). Preferably, the cross-sectional shape of the modified plunger end 78 (and / or 112) is a polygon, such as a triangle (which may be an equilateral triangle), rhombus, square, rectangle, kite, trapezoid, pentagon, hexagon, heptagon, octagon, nonagon, decagon, etc. Typically, the interior angles of such modified plunger end 78 (and / or 112) are between about 60 degrees and about 144 degrees.

[0042] In a further aspect of the disclosure, an insertion end 108 of a plunger 80 is provided. The plunger 80 is generally cylindrical. The insertion end 108 has a modified end 78 that creates at least three vertices 74 at the insertion end 108 and / or consumer end 110 of the plunger 80. The modified plunger end 78 (and / or 112) has up to ten vertices. The modified plunger end 78 (and / or 112) is a polygon, such as, for example, a triangle, a square, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, etc. In a first embodiment, the diameter 76 of a circumscribed circle (shown in dashed lines in Figures 13-19) about the polygon is between about 9.25 mm and about 10.25 mm, more preferably 9.5 mm to about 10 mm, or about 9.75 mm. In another embodiment, the diameter 76 of the circumscribing circle (shown in dashed lines in FIGS. 13-19) for the polygon is between about 6 mm and about 7.25 mm, more preferably about 6.25 mm to about 7 mm, or about 6.5 mm to about 6.9 mm. Deforming the insertion end 108 and / or consumer end 110 of the plunger 80 outside the taught ranges may lead to insufficient retention and / or tearing of the plunger 80.

[0043] The side length 72 of the modified plunger end 78 (and / or 112) is between about 1 mm and about 10 mm, or between about 3 mm and about 8 mm, or between about 4 mm and about 6 mm. The overall circumference of the modified plunger end is between about 18 mm and about 30 mm, which is substantially similar to the circumference of the non-deformed portion of the plunger. The height 111 of the modified plunger end 78 (and / or 112) is up to about 5 mm, or between about 0.5 mm and about 5 mm, or between about 0.5 mm and about 3 mm, or between about 2 mm and about 5 mm. The ratio of the length of the modified plunger end to the total plunger length is between about 0.2% and up to about 1%. The ratio of the length of the modified plunger end to the length of the inner surface of the applicator barrel into which it fits is about 50% to 100%.

[0044] The modified plunger end 78 (and / or 112) is superior to conventional formed ends in providing better retention (preventing the plunger from slipping out of the applicator barrel 122 during use, which can cause the frustrating and unnecessary step of reinserting the string through the plunger 80 and reinserting the plunger 80 into the applicator barrel 122). Samples of the present disclosure exhibit retention forces of greater than 240g, or greater than 245g, or greater than 250g, or greater than 275g, or greater than 300g, or up to about 325g, or between about 240g and about 325g, or between about 245g and about 320g, or between about 245g and about 320g. In one embodiment, the plunger removal force is about 247g. In another embodiment, the plunger removal force is about 318g. In contrast, the PLAYTEX® SIMPLY GENTLE GLIDE® product, tested in the same manner, has a retention force of approximately 238 g.

[0045] In addition to the need to have a strong retention force, it is also desirable to have a sufficient collapse force, and the plunger 80 of the present disclosure is superior in this regard over prior art plungers.

[0046] In a further embodiment of the present disclosure, a compact plunger (not shown) is provided that includes a telescoping two-piece plunger (comprising plunger 80). The two-piece plunger includes an inner plunger and an outer plunger. The inner plunger is typically rearward of and / or nested (telescopically) within the outer plunger. The outer plunger is typically forward of and / or nested within the grip region, transition region, and / or barrel region of the applicator barrel. The two-piece plunger is selectively positionable into undeployed and deployed configurations.

[0047] In some embodiments, each of the insertion ends of the inner and outer plungers are deformed to allow retention. Optionally, the rear finger grip end of the inner plunger is deformed. When the user retracts (or pulls back) the inner plunger, the deformed end locks the inner plunger into place within the outer plunger via a friction and / or interference fit. Similarly, the deformed insertion end of the outer plunger engages the interior of the applicator barrel (barrel region, transition region, and / or grip region). Once the inner and outer plungers are fully deployed and locked, the user can grasp and push the fully assembled plunger, which exerts a force on the distal end of the pledget, expelling it from the applicator.

[0048] The applicator barrel 122 and plunger 80 are assembled by inserting the plunger 80 into the applicator barrel 122 through either the insertion end 130 or the plunger end 128 of the gripping area 132. Such assembly may be accomplished, for example, with a Hauni HP400 machine. For clarity, the barrel 122 is not formed (i.e., the petals 138 of the insertion end 130 are not curved or domed, and are therefore straight as in FIG. 30). For clarity, the tampon 10 has not yet been inserted into the applicator barrel 122. FIG. 27 is an exemplary schematic diagram of an apparatus used to assemble the applicator barrel 122 and plunger 80, including a drum as described below. FIG. 28 is a detailed schematic diagram of an exemplary apparatus showing reshaping tools 82a and 82b. The tampon-applicator assembly 120 is transported through a rotating vacuum drum 114, which has a drum pitch diameter of about 390 mm. Other vacuum drums of different dimensions are possible, but cycle times will vary. As the applicator assembly 120 is transferred onto the main rotating vacuum drum 114, the main product carriage and main reforming tool 82 advance and introduce both the consumer end (which in some embodiments is a rolled end or an inwardly rolled end) and the insertion end 108 of the plunger 80 (which is deformed into a polygonal shape). The reforming tool 82 then advances independently of the main carriage and forms a deformed end 78 at the insertion end 108 of the plunger 80, thereby improving retention and preventing the plunger 80 from accidentally slipping out of the applicator barrel 122. Optionally, the reforming tool 82 simultaneously provides either a deformed end, a rolled end, or a crimped end at the consumer end 110 of the plunger 80 (while providing the polygonal deformed end 78 at the insertion end 108 of the plunger 80). In this manner, the plunger 80 is deformed (or shaped, or rolled) while telescopically engaged within the applicator barrel 122. Thus, the reforming tool 82 has an outer geometry that is smaller than the inner geometry of the applicator barrel 122. For embodiments employing the consumer end 110 of the roll 112, the reforming tool 82 should be heated to at least 175° F., and more preferably to about 180° F. or greater.The time required to deform, shape, or roll the end 110 of the plunger 80 is approximately between about one-half second and about four seconds, which corresponds to a full inward stroke of the reforming tool 82. Once the plunger 80 is fully formed or deformed, or sometimes both, the reforming tool 82 retracts fully from the applicator barrel 122 and the carriage moves outward to pull the plunger 80 away from the roll tool so that it can be transported horizontally to the next adjacent drum for the inspection process. After the inspection process is complete, the tampon applicator is loaded with the pledget and the insertion end of the applicator barrel 122 is closed with the applicator dome forming tool.

[0049] According to one aspect of the disclosure, an apparatus for forming the insertion end 108 and / or consumer end 110 of the plunger 80 is provided and is referred to as a reforming tool 82. The reforming tool 82 is generally illustrated by exemplary FIGS. 22-28. FIGS. 25-26 include exemplary, but non-limiting dimensions of a reforming tool according to the disclosure. The reforming tool 82 includes a forming die for forming the insertion end 108 and / or consumer end 110 of the plunger 80. In certain embodiments, there are two reforming tools 82, a first reforming tool 82a that forms the insertion end 108 into the initial, generally other than cylindrical shape of the plunger 80, and a second reforming tool 82b that forms the consumer end 110 into the initial, generally other than cylindrical shape of the plunger 80, with the first and second insert dies providing different shaped ends (hence the first and second dies are different).

[0050] In certain embodiments, a single reshaping tool 82 has two ends with distinct configurations that provide two different shaped ends. In addition to the reshaping tool(s) 82, the apparatus further includes the machine and rotating vacuum drum 114 described above. The reshaping tool 82 has an outer cylindrical portion 84 with an outer diameter 86 of between about 12 mm and about 19 mm, or between about 14 mm and about 18 mm, or between about 15 mm and about 17 mm, and an outer height 88 of between about 3 mm and about 6 mm, or between about 3 mm and about 5 mm, or between about 4.5 mm and about 5 mm.

[0051] The reshaping tool 82 has a concave intermediate portion 90 adjacent and on the inside of the outer cylindrical portion 84, the concave intermediate portion 90 having a height 92 less than the outer height. The height 92 of the concave intermediate portion 90 is between about 0.5 mm and about 4 mm, or between about 0.5 mm and about 1.5 mm, or between about 2.5 mm and about 3.5 mm. The concave intermediate portion 90 has a width 94 between about 1 mm and about 4 mm. The concave intermediate portion 90 optionally has a tapered geometry such that an upper end 118 has a greater width than a lower end 119. The lower end 119 optionally has a radius of curvature 116 of about 0.5 mm to about 1.5 mm, or about 1.0 mm. The taper angle 115 between the upper end 118 and the tapered intermediate portion 90 is between about 30 degrees and about 50 degrees, between about 35 degrees and about 45 degrees, or about 40 degrees.

[0052] Inwardly and adjacent to the concave intermediate portion 90 is a generally cylindrical central portion 96 having a tapered oriented end 98. The central portion 96 has an upper end surface 95 having a diameter of about 3 mm to about 5 mm, or about 3.25 mm to about 4 mm. The central portion 96 has a central portion height 100 that is greater than the outer height 88, and the central portion 96 has a base region 102 having a polygonal shape. The polygonal shape has at least three points 105. Each point 105 has a radius of curvature 113 of about 0.5 mm to about 1.5 mm. When the plunger 80 is pressed against the reshaping tool 82, the points 105 deform the plunger end 78 into a polygonal shape having a diameter 76 that is greater than the maximum diameter 106 of the body portion 104. 26, the lip 103 is about 1 mm to about 3 mm or about 1.5 mm to about 2 mm above the base region 102. The lip 103 is a forming surface of the consumer end 110.

[0053] The central taper angle 117 is defined as the angle between the vertical projection parallel to the central axis of the reforming tool 82 between the base regions 102. The central taper angle 117 is between about 5 degrees and about 30 degrees, between about 10 degrees and about 20 degrees, or about 15 degrees. The top taper angle 109 is defined as the angle between the vertical projection parallel to the central axis 99 of the reforming tool 82 and the top beveled surface 97, and is larger than the taper angle 117 to provide additional lead-in for the plunger. The top taper angle 109 is between about 30 degrees and about 60 degrees, or about 40 degrees to about 50 degrees, or about 45 degrees to about 50 degrees.

[0054] As mentioned above and described in more detail, and illustrated in FIGS. 29-31 , the applicator barrel 122 has a length 136 extending between the plunger end 128 and the insertion end 130. The barrel 122 includes a grip region 132, a transition region 134, a body region 136, an insertion end region 137 having a plurality of petals 138, and an interior cavity 140 extending between the insertion end 130 and the plunger end 128. The transition region 134 has a length 135 and is disposed between the body region 136 and the grip region 132. The petals 138 are disposed between the insertion end 130 and the body region 136. The body region 136 extends from the petals 138 to the transition region 134, and the grip region 132 extends from the plunger end 128 to the transition region 134.

[0055] In some embodiments, the body region 136 is defined by a circumferentially extending body wall 142 having an outer surface 144 disposed at a constant outer diameter and an inner surface 146 disposed at a constant inner diameter, for example, the wall 142 has a generally constant thickness between about 0.5 mm and about 4 mm. The consumer end 110 has a wall thickness between about 0.5 mm and about 4 mm. In some embodiments, the consumer end 110 has a wall thickness that is greater than the wall thickness of the body region 136, especially if the consumer end 110 is a roll end 112. The wall thickness of the insertion end 108 is preferably between about 0.5 mm and about 4.0 mm. In some embodiments, the insertion end has approximately the same wall thickness as the body region 136. The inner surface 146 having a constant inner diameter along the body wall 142 can help cause consistent expulsion of the tampon 10 into the user's body. In other words, the generally constant inner diameter helps to avoid situations where the tampon 10 may wobble (i.e., where the outer diameter of the tampon 10 is smaller than the inner diameter) as the integral plunger 80 expels the tampon 10 from the barrel 122 of the applicator 120. The inner surface 146 of the body wall defines a portion of the interior cavity 140 of the barrel 122. In some embodiments, the body region 136 is defined by a body wall 142 having a tapered configuration, with the outer surface 144 disposed at a first outer diameter adjacent the transition region 134 and at a second outer diameter adjacent the insertion end 130 of the petals 138, the first outer diameter being greater than the second outer diameter, for example, the body region 136 has a decreasing taper in a direction from the transition region 134 toward the insertion end region 137 with the petals 138, and / or has a decreasing taper in a direction opposite to the direction in which the transition region 134 tapers (i.e., the transition region 134 tapers toward the grip region 132). A barrel 122 with a varying exterior geometry (i.e., varying along the outer surface 144) can provide an improved user experience when the product is used (i.e., inserted and / or removed) from the user's body. FIGS. 29-31 show a body region 136 having a generally circular cross-section. The present disclosure is not limited to a body region 136 having a circular cross-sectional shape.

[0056] The grip region 132 is defined by a circumferentially extending grip wall 148 having an inner surface 150 disposed at a constant inner diameter and an outer surface 152. The grip wall inner surface 150 defines a portion of the interior cavity 140 of the barrel 22. The grip region 132 has a length 154 extending between the plunger end 128 and the transition region 134, which is typical for a full length barrel 122. In some embodiments, the grip wall outer surface 152 can have a constant outer diameter. In some embodiments, the grip wall outer surface 152 can include a protrusion 153 extending radially outward from the outer surface 152 to, for example, facilitate a user's grip of the device. In some embodiments, the grip area 132 can include an outwardly flared section 156 disposed at the plunger end 128, for example, the outwardly flared section 156 can transition from an outer diameter of the grip area 132 to a second diameter that is continuous with the plunger end 128, the second diameter being greater than the outer diameter of the grip area 132. The outer diameter 174 of the flared section 156 is at least about 0.050 inches (about 1.3 cm) greater than the diameter 170 of the recess of the grip area 136. Preferably, the outer diameter 174 of the flared section 56 is at least about 0.075 inches (about 0.2 cm) greater than the outer diameter 170 of the recess of the grip area 36. More preferably, the outer diameter 174 of the flared section 56 is at least about 0.100 inches (about 0.2 cm) greater than the outer diameter 170 of the recess of the grip area 36. In a preferred embodiment, the length 154 of the grip area 132 is greater than 0.5 inches (12.7 mm). In other preferred embodiments, the length 154 of the gripping region 132 is also less than 0.8 inches (20.3 mm). In yet other preferred embodiments, the gripping region 132 can have an inner diameter that varies along the inner surface 150 and / or an outer diameter that varies along the outer surface 152.

[0057] The transition region 134 is defined by a circumferentially extending transition wall 158 having an outer surface 160 and an inner surface 162. The inner surface 162 of the transition wall defines a portion of the interior cavity 140 of the barrel 122. The outer surface 160 is disposed at an outer diameter that changes from the grip region 132 to the body region 136. For example, the outer diameter of the transition wall 158 at the interface with the grip region 132 can be equal to the outer diameter of the outer surface 152 of the grip region and can taper outwardly toward the body region 136. At the interface with the body region 36, the outer diameter of the transition wall 158 can be equal to the outer diameter of the outer surface 144 of the body region. The transition region 134 generally has a length 135 of about 0.100 inches (about 0.2 cm) to about 0.500 inches (about 1.3 cm).

[0058] The multiple petals 138 can be integrally attached to the body region 136 of the barrel 122. The present disclosure is not limited to any particular number of petals 138 or any particular petal configuration. In other words, the applicator of the present disclosure can have 2, 3, 4, 5, 6, 7, 8 or more petals 138 depending on several factors such as the desired expulsion force of the tampon 10 and / or the column strength that the integrally deployed plunger 80 can provide. In some embodiments, the petals 138 and / or the insertion end region 144 can have a generally elongated or tapered shape, thereby promoting comfortable insertion. The tampon has an insertion end 44 opposite its withdrawal end 46. In some embodiments, the tampon 10 can have an insertion end 44 having a complementary tapered or elongated shape. Such shapes can include elliptical, hyperbolic and / or parabolic curves, where the curve follows the contour of the petals 138 or the tampon insertion end 44 .

[0059] 29-31 are exemplary embodiments of an applicator having various dimensions, all within the ranges of dimensions described throughout this disclosure. The overall barrel length 176 is about 2.85 inches (about 7.2 cm) to about 2.9 inches (about 7.4 cm), the grip region 132 has a length 154 of about 0.5 inches (about 1.2 cm) to about 0.8 inches (about 2 cm), the body region 136 has an outer diameter 172 adjacent to the transition region 138 of about 0.47 inches (about 1.2 cm) to about 0.6 inches (about 1.5 cm), and the plunger end 128 has an outer diameter 174 of about 0.47 inches (about 1.2 cm) to about 0.65 inches (about 1.7 cm).

[0060] Optionally, the insertion end region 137 has elongated tapered petals with a taper ratio of about 0.3 to about 1.0, where "taper ratio" is defined as the radius 178 of the insertion end region 137 at the base of the petals 38 (i.e., the cut between the end of each petal and the body region) divided by the length 180 of the insertion end region 137 (i.e., the length from the tip end 179 of the petals to the base 139 of the petals 138).

[0061] In some embodiments, the tampon 10 can have a reduced overall length to allow for increased flexibility in barrel design, such that one or more full-sized barrel components (or at least one or more barrel components having characteristics closer to a full-sized applicator than known miniature applicators) can be utilized in the miniature applicator configuration. The tampon 10 can be radially and axially compressed and formed at a reduced length relative to known tampons used with miniature applicators. Despite having a reduced length, the tampon 10 achieves comparable absorbency to existing tampons in both full-sized tampon-applicator assemblies and miniature applicator assemblies.

[0062] Those skilled in the art will appreciate that the compact applicator assembly of the present disclosure can comprise a number of materials and aesthetics. In particular, it may be advantageous to use aesthetics to create distinctions between components of the applicator system. For example, in one embodiment, the grip area can have distinct aesthetic and / or tactile indicators (i.e., material, texture, color, tone, shade, luminosity, print, pattern, graphic or other visual indicators) relative to the remainder of the applicator barrel to aid the user in identifying where and how to hold the tampon applicator. In another embodiment, one or more portions of the applicator assembly are at least partially translucent to aid the user in identifying where the sides of the applicator are (i.e., where the tampon 10 and / or tampon string are located within the applicator and / or where the inner sleeve is located in a compressed configuration versus a deployed configuration). In a further embodiment, the inner sleeve and outer sleeve can have different visual and / or tactile indicators.

[0063] Although the present invention has been shown and described with reference to specific embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention.

Claims

1. A tampon applicator assembly, comprising: a pledget, the pledget having an absorbency between about 6 g and about 9 g and a basis weight between about 120 gsm and about 145 gsm, or the pledget having an absorbency between about 9 g and about 12 g and a basis weight between about 160 gsm and about 190 gsm, the grams / gram absorbency being between about 5 g / g and about 6 g / g; a plunger for a tampon applicator having an insertion end and a consumer end generally opposite said insertion end, said plunger having a body portion between said insertion end and said consumer end, said insertion end being transformed from a generally cylindrical shape to a polygonal shape, a circumscribing circle having a diameter between about 9.25 mm and about 10.25 mm, said body portion being generally cylindrical after said insertion end is transformed, and said length of said insertion end being between about 0.5 mm and about 5 mm; 1. A tampon applicator assembly comprising:

2. A standard pledget having an absorbency of between about 6 g and about 9 g, the pledget has a basis weight of between about 120 gsm and about 145 gsm; The gram / gram absorbency is between about 5 g / g and about 6 g / g; A pledget comprising:

3. The pledget comprises fibers; The fibers are cotton or rayon or a combination thereof; The pledget of claim 2.

4. The pledget comprises 100% cotton fibers. The pledget of claim 3.

5. the pledget has a cross-pad configuration having at least two pads; Each of the at least two pads comprises the fibers; The fibers are cross-wrapped to form at least two layers and are needle punched at about 40 punches per square centimeter to about 80 punches per square centimeter. The pledget of claim 3.

6. The at least two pads have a length between about 7.6 cm and about 12.7 cm and a width between about 2.54 cm and about 7.6 cm.

6. The pledget of claim 5.

7. each of said at least two pads comprises 100% cotton; The pledget of claim 6.

8. 1. A super pledget having an absorbency of between about 9 g and about 12 g, the pledget has a basis weight of between about 160 gsm and about 190 gsm; The gram / gram absorbency is between about 5 g / g and about 6 g / g; A super pledget characterized in that

9. The pledget comprises fibers; The fibers are cotton or rayon or a combination thereof; 9. The pledget of claim 8.

10. The pledget comprises 100% cotton fibers.

10. The pledget of claim 9.

11. the pledget has a cross-pad configuration having at least two pads; Each of the at least two pads comprises the fibers; The fibers are cross-wrapped to form at least two layers and are needle punched with at least 80 punches per square inch.

10. The pledget of claim 9.

12. The at least two pads have a length between about 7.6 cm and about 12.7 cm and a width between about 2.54 cm and about 7.6 cm. The pledget of claim 11.

13. each of said at least two pads comprises 100% cotton; The pledget of claim 12.

14. 1. A plunger for a tampon applicator having an insertion end and a consumer end generally opposite the insertion end, comprising: the plunger having a body portion between the insertion end and the consumer end; the insertion end is transformed from a generally cylindrical shape to a polygonal shape; a diameter of a circumscribing circle of the polygonal shape is between about 9.25 mm and about 10.25 mm; the body portion is generally cylindrical after the insertion end is deformed; the length of the insertion end is between about 0.5 mm and about 5 mm; 1. A plunger for a tampon applicator.

15. the consumer end is rolled such that the thickness of the consumer end is greater than the thickness of the body portion; The thickness of the consumer end is between about 0.5 mm and about 4 mm.

15. The plunger for a tampon applicator according to claim 14.

16. The insertion end has at least three vertices.

15. The plunger for a tampon applicator according to claim 14.

17. Each of the at least three vertices has a radius of curvature of about 0.5 mm to about 1.5 mm.

17. The plunger for a tampon applicator of claim 16.

Images