Tampon applicator with improved insertion tip

Abstract

To provide a tampon applicator assembly, including a tampon applicator and a tampon pledget.SOLUTION: The invention relates to an insertion end for a tampon applicator assembly. The insertion end has an insertion tip region and optionally an inflection region. The insertion end of the tampon applicator assembly is unique in one or more ways, including one or more of the following: having a unique degree of closure, an inflection region length that is different than an insertion end region length, petal slits that form a tear-drop shape, petals having multiple radii of curvature, the insertion end having a unique radius of curvature, the insertion end having a unique part thickness.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a tapered tampon applicator having an improved insertion tip that allows for increased comfort and reliability during use. CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 62 / 365,564, filed July 22, 2016. [Background technology]

[0002] Commercially available tampon applicators are generally formed of two components: a barrel in which an absorbent pledget is held, and a plunger. The barrel is blunt-opening, but often has a rounded, e.g., dome-shaped, insertion end and typically includes multiple petals that open when the pledget is pressed against it during expulsion. In contrast to blunt-opening designs, a tapered insertion end is preferred for ease and comfort of insertion for the user.

[0003] U.S. Patent No. 6,277,949 discloses a tampon applicator having a plunger and a barrel with a tapered insertion tip, as opposed to a generally spherical tip, that provides improved insertion comfort. The taper of the insertion tip is determined by the ratio of the length of the tapered protrusion along the longitudinal axis of the barrel to the length of the tapered protrusion along the radius of the barrel at the base region of the insertion tip. The insertion end of the barrel preferably includes two or more petals having a substantially uniform thickness. Through both qualitative and quantitative consumer research, it has been found that providing a tapered insertion tip significantly improves the actual perceived level of comfort associated with inserting a tampon applicator. Tampon applicators can be made from a variety of materials, including cardboard and thermoplastic polymers.

[0004] Furthermore, the '699 patent further discloses that petal thickness affects two major factors in tampon performance: ejection force, i.e., the amount of force a user applies to the plunger to expel the pledget from the applicator, and petal tip stability. Generally, ejection forces greater than 25 oz are unacceptable to consumers, and ejection forces below 20 oz are generally preferred. If the petal tips are unstable, they may open, collapse, or otherwise deform, making the tampon uncomfortable to use or even rendering the tampon unusable. The thickness of the applicator petals can be varied to affect the applicator's ejection force and / or petal stability. Thin petals, especially those less than about 0.022 inches thick, tend to reduce ejection force, and reducing petal thickness can further reduce ejection force.

[0005] On the other hand, thinner petals may face tip stability issues or collapse inward during insertion if the applicator material is not sufficiently stiff or rigid. The petals of the '666 patent have a thickness of about 0.004 to about 0.022 inches, preferably about 0.008 to about 0.018 inches, and more preferably about 0.009 to about 0.013 inches. Increasing petal thickness above about 0.025 inches can help improve petal stability and / or collapse issues, which is disclosed to increase ejection force.

[0006] Patent Document 2 discloses a tampon applicator in which the insertion tip includes four to six petals, which are non-linear and separated from one another by slits that are not parallel to the longitudinal axis of the barrel. Linear petals separating the petals are common in many commercially available applicators. As described in Patent Document 2, the petals at the insertion tip are designed to be thin and flexible so that they open with minimal force, so that the petals do not provide significant resistance that makes it difficult to expel the tampon from the tampon applicator.

[0007] For this reason, as noted in U.S. Patent No. 6,277,623, petals are often designed to be "weaker" than the rest of the applicator. However, as noted in U.S. Patent No. 6,277,623, overly weak petals can be damaged during insertion, and some users complain that such petals cause pinching after the tampon is expelled from the applicator. As further noted in U.S. Patent No. 6,277,623, weaker petals are more likely to curve and therefore break the generally dome-shaped surface, which can cause scratches or other damage when the tampon applicator is inserted into the vagina or removed from the vagina after the tampon is expelled.

[0008] U.S. Patent No. 5,699,949 discloses a tampon applicator assembly having an applicator barrel with a tapered insertion tip similar to that of U.S. Patent No. 5,699,949, which is provided with a shaped pledget, e.g., shaped in a manner similar to the shape of the end of the barrel including the insertion tip. Thus, the shaped pledget can be at least partially contained within the insertion tip for support within the petal, helping to prevent deformation of the thin, highly flexible petal that could result in scratching, pinching, etc.

[0009] Although the shaped petals supporting the pledgets of Patent Document 3 can improve comfort for the end user and increase reliability when using a tapered insertion tip and very thin, flexible petals, further improvements are still needed from both a consumer and manufacturer's perspective.

[0010] In addition to the potential for user injury caused by overly fragile petals, efficient mass production of articles with very thin sections can be extremely demanding. For example, many tampon applicators are made by molding thermoplastic polymers, such as polyolefins, or blends of thermoplastics and elastomers. Many polymer compositions that can impart desirable functional and aesthetic properties to tampon applicators, such as flexibility, lubricity, smoothness, and consistent color, can result in excessive waste when using certain molding techniques due to breaking, tearing, or other damage to the article. This is particularly problematic in sections of the article that are delicate, such as thin-walled petals, or that are subjected to high stresses during processing, such as the point where the slits that define the petals intersect with the main body of the barrel.

[0011] The conceptually simple means of creating a structurally stronger applicator by incorporating thicker petals, or petals formed of a slightly stiffer polymer composition, would allow for a more efficient or flexible manufacturing process, while also providing an applicator that is less likely to cause discomfort upon insertion or withdrawal. However, as noted above in the art, incorporating this modification directly into currently constructed tampon applicators would likely increase the ejection force required to actuate the applicator, which would be unacceptable to end users.

[0012] A tampon applicator having a reconfigured tapered insertion tip that can overcome issues related to end-user comfort while operating at an acceptably low ejection force is highly desirable. Typically, an ejection force between 5 oz and 25 oz is desired, with an ejection force between 10 oz and 20 oz usually preferred. It has been found that by providing a wider closure at the end of the insertion tip and / or extending the length of the petals, the force required to eject the pledget from the applicator can be reduced. Making this change to the structure of currently available tampon applicators, even if only slightly, can result in significant improvements in usability and comfort, and can also enable other changes in applicator design and construction, such as the use of thicker or stronger petals, which provide additional improvements to both end users and manufacturers.

[0013] In addition to providing a user-friendly product, particularly in terms of comfort and release force, manufacturing such a product can be equally challenging. Material costs fluctuate as the availability of certain preferred materials fluctuates. Furthermore, tooling to support new products with improved features can be expensive and present problems along with material sourcing issues. Suffice it to say, it is desirable to have a flexible product strategy that allows manufacturers to choose multiple avenues or options while still resulting in additional, uniquely preferred and / or improved consumer products. [Prior art documents] [Patent documents]

[0014] [Patent Document 1] U.S. Patent No. 8,444,590 [Patent Document 2] U.S. Patent No. 8,162,872 [Patent Document 3] U.S. Patent No. 9,192,522 Summary of the Invention

[0015] A tampon applicator assembly is provided that includes a tampon applicator and a tampon pledget. The tampon pledget has an insertion end and a rear end. The rear end generally includes a withdrawal string. The insertion end is optionally tapered.

[0016] The tampon applicator assembly defines a straight, central longitudinal axis extending axially along its length. The tampon applicator is substantially straight along this central longitudinal axis, and the applicator components are coaxial about this straight, central longitudinal axis. The tampon applicator includes a barrel and a plunger. The plunger is a single piece, or optionally a two-piece plunger. In either configuration, the plunger telescopically engages a tampon pledget housed within the barrel, or stated differently, the plunger telescopically engages the barrel and applies force to the rear end of the tampon pledget. In configurations having a two-piece plunger, the plunger segment (i.e., the inner segment) telescopes within the other segment (i.e., the outer plunger), providing a shorter applicator footprint in an unused or stored state.

[0017] The barrel includes an insertion end, a main body region, and optionally an inflection region. The insertion tip region and the inflection region may be separate, overlapping, or coincident. In either embodiment, the insertion tip region defines the length of the petal (i.e., the length from the free end of the petal to the base where the slits separating the petals terminate), while the inflection region defines a length corresponding to the inflection curvature of the insertion end of the barrel. The applicator has between three and eight petals that define the insertion end.

[0018] The insertion end through the petals defines a closed geometric shape, or stated another way, defines the amount of space between the free ends of the petals. The closed geometric shape is defined by the inscribed shape between the petal tips, which is generally a polygonal shape. For example, if the insertion end has four petals, the inscribed polygon resembles a quadrilateral. The closed geometric shape (defining a polygon) further defines a circle inscribed within the polygon. The diameter of the circle is between about 0.075 inches and about 0.150 inches.

[0019] A circular or elliptical insertion tip opening (i.e., defined by a slice along the longitudinal axis of the applicator) is defined by a circle or ellipse inscribed within a regular polygon, where the terminal ends (i.e., free ends) of the petals represent the midpoints or endpoints of each side of the polygon. For example, for a barrel having a generally circular interior region and an insertion end defined by four petals, the insertion end opening is a circle inscribed within a square, where the terminal ends of the petals represent the midpoints of each side of the square. In an embodiment having five petals, the insertion end defines the endpoints of a pentagon, and since the circle is inscribed within the pentagon, the circle touches the midpoints of each side of the pentagon.

[0020] The degree of closure is defined as the ratio of the inscribed circle, as defined by the free ends of the petals, to the cross section of the base region of the petals. Stated differently, the degree of closure is the ratio of the diameter of the insertion end opening to the corresponding diameter of the hollow interior of the main body in the region where the insertion tip abuts the main body. This ratio compares the relative diameters of the inscribed circles. The degree of closure is between about 0.1 and about 0.3, or between about 0.1 and about 0.25, or from about 0.12 to about 0.20, or from about 0.14 to about 0.20.

[0021] For example, for a tampon applicator barrel having a generally circular interior region and a generally circular insertion tip opening, closure is the ratio of the diameter of the insertion tip opening to the diameter of the interior of the barrel where the insertion end is adjacent the main body. For example, a closure of 0.1 means that the insertion tip opening is 1 / 10 the size of the interior of the barrel at a point within the region where the insertion end is adjacent the main body. For a circular opening defined by an even number of petals, this is also the distance between the ends of two opposing petals.

[0022] As described above, the insertion tip region and the inflection region may be separate, overlapping, or coincident. Thus, the insertion tip region and / or the inflection region may have a taper ratio greater than about 1.0, or from about 1.3 to about 3.5, e.g., from about 1.3 to about 2.5, from about 1.5 to about 2.5, from about 1.7 to about 2.3, or from about 1.6 to about 2.2. The taper ratio may be determined by the shape of the applicator (i.e., the petals are formed into a curved shape).

[0023] Thus, the length of the shaped insertion tip region is the axial length between the shaped petal free ends where the slits (or cuts) separating the petals from one another terminate. The taper ratio of the insertion tip is the ratio of the shaped insertion tip region length to the radius of the barrel where the slits separating the petals terminate. The insertion tip taper ratio is greater than about 1.0.

[0024] The shaped inflection region length is the length between where the insertion curve ends and where the slit separating the petals from one another terminates. In some embodiments, the inflection taper ratio is the ratio of (a) the sum of the shaped insertion tip region length and the shaped inflection region length to (b) the greater of the radius of the barrel where the insertion curve ends and the radius where the slit between the petals terminates. The inflection taper ratio is greater than about 1.0.

[0025] The length of the shaped insertion tip region is not equal to the length of the shaped inflection region. In some embodiments, the length of the shaped insertion tip region is greater than the length of the shaped inflection region. In other embodiments, the length of the shaped insertion tip region is less than the length of the shaped inflection region. The length of the insertion tip region is different from the length of the inflection region. The main body region has a taper that is distinct from the insertion tip region and / or the inflection region. In some embodiments, the main body region is surrounded by substantially straight walls and does not have a taper. In some embodiments, the main body region has a linear taper, while the insertion curve is nonlinear. In some embodiments, the insertion curve is different from the curvature of the taper of the main body region. As described herein, the insertion curve, in some embodiments, has multiple radii of curvature. In some such embodiments, the radius of curvature adjacent to the main body region has a different radius of curvature than the main body region. In other such embodiments, the insertion curve defines a general curvature equation that is different from the taper equation defined by the main body region. Thus, in embodiments where the main body region is not substantially straight, one skilled in the art will be able to identify where the insertion curve ends and where the main body region begins.

[0026] Also provided is a tampon assembly including a tampon applicator of the present disclosure and an absorbent pledget held within the applicator barrel, wherein a force of about 5 ounces to about 25 ounces, i.e., about 1.4 Newtons (N) to about 6.9 Newtons (N), is required to expel the pledget, for example, a force of about 8 oz to about 20 oz, i.e., 2.2 N to 5.6 N, for example, about 10 oz to about 20 oz, i.e., 2.8 N to 5.8 N, about 10 oz to about 15 oz, i.e., 2.8 N to 4.2 N, or about 10 oz to about 12 oz, i.e., 2.8 N to 3.3 N, is required to expel the pledget.

[0027] In the case of an oval barrel and an oval insertion tip opening, the ratio is determined by the widths of the corresponding parts inside the barrel and the insertion tip opening, e.g., the widest length in each or the narrowest length in each.

[0028] The insertion tip taper ratio is defined as the ratio of the length of the tapered projection along the longitudinal axis of the barrel to the tapered projection along the radius of the barrel at the base region of the insertion tip, i.e., the region where the insertion tip region (and / or inflection region) abuts the main body of the barrel. For a generally circular barrel, this translates to the ratio of the length of the insertion tip to the radius of the circumscribed circle of the barrel at the base of the insertion tip. For the purposes of this disclosure, the taper ratio of an elliptical barrel is the ratio of the length of the insertion tip to the radius of the barrel at its widest point at the base of the insertion tip.

[0029] In some cases, the degree to which the insertion tip opening is enlarged or the overall petal length is increased depends, in part, on the shape of the petal. Petals of the present disclosure have, in their unshaped (i.e., straight) state, approximately triangular, semicircular, parabolic, elliptical, and / or hyperbolic shapes, and in some embodiments, a portion of the petal, for example, near the base of the petal, has an approximately linear shape. In some embodiments of the present disclosure, it has been found that providing a more or more rounded petal end, a longer linear region, or a less steep parabolic curve can have an effect on ejection force, and in some embodiments, adjustments are made to the petal design to account for these interactions. In other embodiments, two adjacent petals converge in the barrel region (i.e., at the base of the petal) to form a teardrop shape. In yet other embodiments, one or more petals have more than one radius of curvature, such that at least one of the one or more radii has an approximately parabolic, hyperbolic, and / or elliptical shape. In some embodiments, the petals have at least two radii of curvature, at least three radii of curvature, or at least four radii of curvature.

[0030] Thus, the applicators of the present disclosure have an improved tapered insertion tip configuration that provides the comfort associated with tapered applicators, which also reduces the ejection force of the applicator. Using a configuration with a lower ejection force also enables other changes to design and composition, such as reducing the need for very thin or fragile petals, which may result in less tip deformation and greater comfort during use. [Brief explanation of the drawings]

[0031] [Figure 1] 1 shows a tampon applicator having a rounded or dome-shaped insertion tip. [Figure 2] 1 shows a tampon applicator with a tapered insertion tip. [Figure 3] 1 shows a tampon applicator with a tapered insertion tip. [Figure 4] 1 shows a tampon applicator with a modified insertion tip. [Figure 5] 1 shows a tampon applicator having a rounded or dome-shaped insertion tip. [Figure 6A] 1 is a schematic representation of a cross-sectional view of an applicator insertion tip and inflection region. [Figure 6B] 1 is a schematic representation of a cross-sectional view of an applicator insertion tip and inflection region. [Figure 6C] 1 is a schematic representation of a cross-sectional view of an applicator insertion tip and inflection region. [Figure 7] 1 is a schematic representation of a cross-sectional view of an applicator insertion tip and inflection region. [Figure 8] 1 is a schematic representation of a cross-sectional view of an applicator insertion tip and inflection region. [Figure 9] 1 is a schematic representation of a cross-sectional view of an applicator insertion tip and inflection region. [Figure 10] FIG. 10 is a front view of the applicator insertion tip and inflection region. [Figure 11] FIG. 10 is a front view of the applicator insertion tip and inflection region. [Figure 12]FIG. 10 is a front view of the applicator insertion tip and inflection region. [Figure 13] FIG. 10 is a detailed view of the applicator insertion tip and inflection region. [Figure 14] 1 is a line cross-section of a compact applicator assembly in a compact or stowed configuration. [Figure 15] 1 is a line cross-section of the compact applicator assembly in an expanded or ready configuration. [Figure 16] 1 is a line cross-section of a compact applicator assembly with a pledget being ejected from the applicator. [Figure 17] FIG. 1 is a diagram of a petal configuration. [Figure 18] FIG. 1 is a diagram of a petal configuration. [Figure 19] FIG. 10 is a partial oblique view of the insertion tip and the inflection region. [Figure 20] FIG. 10 is a partial oblique view of the insertion tip and the inflection region. DETAILED DESCRIPTION OF THE INVENTION

[0032] The tampon applicator assembly 10 of the present disclosure shares many general features with tampon applicators known in the art, namely, a plunger 16 and a barrel 14 having a generally tubular shape defining a hollow cavity 15 and two opposing ends 44, 84 (a forward-most end 44 and a rearward-most end 84), each end 44, 84 including an opening. The barrel 14 includes an insertion end 26, a main body region 36, and one or more of a reverse taper region 38 and a gripping region 40. The main body region 36 has a length 72, the finger grip region 40 has a length 74, and the reverse taper region 38 has a length 76. The tampon applicator 12 includes a plunger 16 slidably disposed within the hollow cavity 15 and the rearward-most end 84. The forward-most end 44 defines an insertion end 26. The insertion end 26 includes a plurality of petals 45. The petal 45 is initially in an unformed or straight position and, after assembly of the tampon applicator assembly 10, is fully completed (i.e., at least the tampon pledget 22 is inside the hollow cavity 15, as shown in at least FIG. 7), and the insertion end 26 is closed or formed. When the pledget 22 contained within the barrel 14 is forced against the petal 45 (by pressure applied by the plunger 16), the insertion end 26 opens, enlarging the opening 30 at the forward-most end 44 of the insertion end 46 through which the pledget 22 can be expelled. The pledget has a withdrawal end 28 and includes a withdrawal string 24.

[0033] The tampon applicator 12 may be a full-sized applicator 12 having a full-sized barrel 14 and, optionally, a one-piece plunger 16 as shown in FIG. 1, and / or a compact applicator as shown in FIGS. 14-16. The compact applicator may have a one-piece plunger (not shown in FIGS. 14-16) and / or a two-piece plunger 16 as shown in FIGS. 14-16. The two-piece plunger includes an inner plunger 18 and an outer plunger 20, where the inner plunger 18 telescopically engages the outer plunger 20. Both the inner plunger 18 and the outer plunger 20 telescopically engage the barrel 14 when in the connected / extended configuration. Optionally, the compact applicator may have a full-sized barrel 14 as shown in FIGS. 2-5. The tampon applicator 12 can be made from a variety of materials, including cardboard, thermoplastics, and / or elastomeric polymers, and the applicator 12 can also be coated with materials that can further aid in the comfort or usefulness of the applicator 12.

[0034] For example, Figure 1 shows a well-known tampon applicator 12 having a plunger 16 and a barrel 14 that includes a textured finger grip area, a main body region 36, and an insertion end 26. In Figure 1, the plunger enters the barrel 14 through the finger grip area 40.

[0035] To improve ease of insertion of the applicator 12, the structure of the insertion end 26 has been reconfigured. Prior to actuation of the applicator 12 and after assembly of the components of the tampon applicator assembly, the insertion end 26 has a defined taper, length, and closure. These characteristics are determined by the shape and length of the individual petals 45 and / or the inflection curve 54. Differences between the tampon applicator 12 of the present disclosure and those of the prior art can include one or more of the following: the introduction of an inherent or greater degree of closure at the forward-most end 44 of the insertion end 26; the extension of the petals 45 forming the insertion end 26; or the extension of the inflection curve 54; the inclusion of an inherent petal gap 51; and / or the use of differently shaped petals 45 (i.e., curvature, width, thickness). With regard to the latter, differently shaped petals include petals 45 having different or multiple radii of curvature, differently shaped slits 48, or slits 48 with different radii of curvature. In such an embodiment, the shape of the petals 45 provides an insertion end 26 with a unique inflection curve 54 and / or multiple radii of curvature.

[0036] The insertion end 26 includes an insertion tip region 32 and, optionally, an inflection region 34. The insertion tip region 32 and the inflection region 34 may be separate, overlapping, or coincident. In any embodiment, the insertion tip region 32 defines a length 62 of the shaped petal 45 (i.e., the length of the free end 46 of the petal 45 to the base 50 where the slit 48 separating the petals 45 terminates), while the inflection region 34 defines a length 66 (i.e., inflection region length 66) corresponding to the inflection curve 54 of the insertion end 26. The applicator 12 has between three and eight petals 45 that define the insertion end 26.

[0037] The insertion end 26 defines a closed geometry via the petals 45, or stated differently, the amount of space between the petal free ends 46. The closed geometry is defined by an inscribed shape 56 between the petal free ends 46 (i.e., the petal tips) and is generally polygonal in shape. For example, if the insertion end 26 has four petals 45, the inscribed polygon 56 resembles a quadrilateral. The closed geometry (which defines a polygon) further defines a circle 58 inscribed within the polygon 56. The diameter 60 of the circle 58 is between about 0.075 inches and about 0.150 inches.

[0038] Figure 1 shows a tampon applicator having a mostly hemispherical insertion end where the curved region is substantially the same as the insertion end (i.e., the length of the inflection curve corresponds to the length of the shaped petals). Figure 2 shows a tampon applicator 12 having a significantly tapered insertion end 26 compared to that of the tampon applicator 12 of Figure 1. The tampon applicator 12 of Figures 2-3 also shows a barrel 14 having a main body region 36 that tapers slightly as it progresses toward the insertion end 26 and more significantly as it progresses toward the finger grip region 40. The applicator 12 of Figures 1 and 4-5 shows a more linear main body region 36.

[0039] The tampon applicator 12 of the present disclosure includes a barrel 14 that includes a linear or tapered main body region 36 and generally includes a textured 42 finger-gripping region 40, although some embodiments lack a distinct textured 42 finger-gripping region 40. The textured 42 finger-gripping region 40 includes ribs, embossings, slits, and / or other three-dimensional topography.

[0040] The tampon applicator 12 of the present disclosure has a tapered insertion end 26 that is defined in part by a taper ratio. The taper ratio is defined by the boundaries of the insertion end 26. That is, if the inflection region 34 extends beyond the insertion tip region 32, the "boundaries" are defined by the length, diameter, and radius of the curve 54 (i.e., the length 62 of the insertion tip region 32, and any additional length 66 provided by the inflection region 34, as well as the diameter 86 and radius 82 of the inflection region). Alternatively, if the inflection region 34 overlaps the insertion tip region 32, the "boundaries" are defined by the length, diameter, and radius of the insertion tip region 32 (i.e., the length 62 of the insertion tip region 32, and the diameter 78 and radius 80 of the insertion tip region 32). Thus, the taper ratio of the insertion tip region 32 is defined by the ratio of the length of the tapered protrusion along the longitudinal axis 11 of the barrel 14 (i.e., the length 62 of the shaped insertion tip region 32) to the length of the tapered protrusion along the radius 80 of the barrel 14 at the termination 50 of the plurality of slits 48 of the insertion end. The taper ratio of the insertion tip 26, including the insertion tip region 32 and the inflection region 34, is defined by the ratio of the lengths of the tapered protrusion along the longitudinal axis 11 of the barrel 14 (i.e., the shaped length 66 of the inflection curve 54, which generally includes the shaped length 62 of the insertion tip region 32 plus or minus the shaped length 66 of the inflection region 34). For example, FIGS. 7, 8, and 9 show schematic diagrams of tapered insertion end 26 as found in the tampon applicator 12 of FIGS. 1-5. For clarity, in Figures 7-9, any number without an "a" or "b" can be designated by either or both "a" and "b." For example, when referring to radius 82, it can be thought of in terms of 82a relative to the outer dimension and 82b relative to the inner dimension (and as shown in Figures 7-9). Main body region 36 of barrel 14 is shown partially to the left of vertical axis 13, which is located at the boundary between insertion end 26 and main body region 36, designated by diameter 86 (which includes radius 82), and insertion end 26 is shown in the curved portion (i.e., inflection curve 54) to the right of diameter 86 (represented by 86a for the outer geometry and 86b for the inner geometry).As shown throughout this disclosure, vertical axis 13 is shown along various locations of the length of tampon applicator assembly 10 (as long as it is perpendicular to longitudinal axis 11). The length of the tapered protrusion along longitudinal axis 11 of barrel 14 is shown by longitudinal axis 11 and designated by lengths 62 and 66, and the length of the protrusion along vertical axis 13 is shown by line radius 82. Tapered insertion end 26 has a taper ratio greater than 1, which is (a) any deviation caused by length 66 of 62 and shaped inflection region 34 divided by (b) radius 82.

[0041] 6A is a schematic diagram of the same portion of a barrel having an essentially hemispherical, dome-shaped insertion end, as discussed below, where the length 49 of petals 45 is approximately equal to the radius 80, resulting in a taper ratio of 1. While a tapered insertion tip (i.e., having a taper ratio greater than 1) is preferred, various embodiments throughout this disclosure have advantages having a taper ratio less than or equal to 1.

[0042] The tampon applicator 12 of the present disclosure has a tapered insertion end 26 having a taper ratio of at least 1.0, or 1.2, or typically at least 1.3, and often 1.4, 1.5, 1.6, 1.7 or greater.

[0043] In some embodiments, it is advantageous to modify the insertion end 26 so that it extends beyond the base region 47 of the petals 45 (i.e., beyond the slits 48 between the petals 45). In these embodiments, the insertion end 26 includes a portion that extends beyond the insertion tip region 32, into the main body region 36, and into the base region 47 of the petal 45, which is the inflection region 34. In these embodiments, the inflection curve 54 extends from the free end 46 of the petal 45, which is defined by (or defines) the insertion tip 26, and continues with a portion of the inflection curve 54 beyond the base region 47 of the petal 45 and into the main body region 36 within the inflection region 34. This portion of the petal between the base region 47 and the main body region 36 is described as the inflection region 54.

[0044] Alternatively, in some embodiments, the inflection region 54 and the insertion tip region 32 overlap and / or at least partially coincide. In some embodiments, the inflection curve 54 terminates at the axial length 62 of the petal 45 between the free end 46 and the base region 47 of the petal 45 (i.e., where the slit 48 between the petals 45 terminates 50). In these embodiments, the inflection region 34 is the portion of the length 66 between the end of the inflection curve 54 and the termination 50 of the slit 48 separating the petals 45.

[0045] 6A-6C show configurations of the present disclosure illustrating variations in insertion end 26. 6A-6C show hypotenuses 88 and 90 corresponding to the radius of insertion end 26. FIG. 6A shows an embodiment of the present disclosure where insertion end 26 corresponds to insertion tip region 32. The axial length 49 of the petal between points "y" and "z" and the radius 80 of the insertion tip region (between points "z" and "x") form a right angle α. Hypotenuse 90 corresponds to points "y" and "z."

[0046] FIG. 6B shows an embodiment of the present disclosure in which the insertion end 26 is “under-formed.” That is, the insertion tip region 32 and the inflection region 34 overlap. The axial length 66 of the inflection region 34 is bounded by “x” and “x′,” and the insertion tip region 32 has an axial length 49 between “x” and “y.” The insertion tip region 32 is shifted the other way due to the under-formed insertion end; now, radius 80 becomes 80′ due to the shift from “z” to “z′.” Angle α is the sum of angles α′ and β, where α′ is formed through the deviation of “z′” and the inflection region 34. As long as the axial length 66 (or 68) of the inflection region is parallel to length l, angle φ is the complementary exterior angle of angle α. Otherwise, angle φ is other than a right angle. 6B shows only the underlying petal geometry of FIG. 6A, but the hypotenuse 88 of the inflection curve 54 is shorter and steeper. In certain embodiments, this reduces ejection forces by having the petal 45 extend beyond the inflection curve 54. In certain embodiments, this improves support for the petal 45, reducing the chance of the petal 45 accidentally flexing.

[0047] FIG. 6C shows an embodiment of the present disclosure in which the insertion end 26 is “over-formed.” That is, the inflection region 34 extends the length of the insertion end 26 beyond the insertion tip region 32. The axial length 66 of the inflection region 34 is bounded by “x” and “x″,” and the insertion tip region 32 has an axial length 49 between “x” and “y.” The inflection region 34 provides an over-formed insertion end 26, where the radius 80 is now 80″ due to the shift from point “z” to “z″.” The angle α is expanded by angle α′, and angle α is the sum of angles α′ and β, where α′ is formed by the deviation of “z″” and the inflection region 34. The angle θ is defined by the radius 80″ and the length l′. FIG. 6C depicts only the underlying petal geometry of FIG. 6A , but the hypotenuse 88 of the inflection curve 54 is longer and more gradual. In certain embodiments, this reduces ejection force, improves insertion comfort, and / or improves support for the petal 45, reducing the chance of accidental flexing of the petal 45.

[0048] FIGS. 7, 8, and 9 illustrate the disclosed configurations with various dimensions of both the inner barrel 14a geometry, the outer barrel 14b geometry, and the barrel 14 thickness 14c. FIG. 7 illustrates hypotenuses 88 and 90 corresponding to the radius of the insertion end 26. FIGS. 8-9 illustrate hypotenuses 88 and 90 corresponding to the diameter of the insertion end 26. While the hypotenuses in these diagrams may vary, those skilled in the art will recognize that the relationship of different geometries, including the hypotenuses, can be depicted in numerous ways as taught by the present disclosure with respect to diameters and radii, and inner and outer dimensions. FIG. 8 illustrates the barrel 14 prior to forming the insertion end 26. FIG. 9 illustrates the barrel 14 with a shaped (i.e., dome-shaped) insertion end 26, where the insertion end 26 is tapered. FIGS. 8 and 9 are diagrammatic representations; other barrel 14 geometries can be similarly described. The inflection region 34 can be described in terms of both the outer geometry 14a and the inner geometry 14b. The exterior geometry 14a relates to how conductive the applicator 12 is, particularly for insertion comfort. The exterior geometry 14a focuses on the correlation of the outer diameter 80a of the barrel 14a, where the slits 48 between the petals 45 terminate, and also the outer diameter 82a of the barrel 14a at the inflection region 34, and how they compare to the length 62 of the formed petals 45 and the length 66 of the inflection region (see, e.g., FIG. 9 for an embodiment with formed petals 45). A longer or more gradual taper can be achieved as long as the length 62 (as formed) between the free ends 46 of the petals 45 and the length 66 of the inflection region 34 (as formed) are greater than the outer radius 82a where the inflection region 34 ends and the main body region 36 begins. In some embodiments, the length between the exterior of the petal free end 46a and the termination 50 of the slit 48 between the petals 45 is greater than the outer radius 82a where the insertion tip region 32 meets the main body region 36. In some embodiments, the length between the exterior of the petal free end 46a and where the inflection region 34 meets the main body region 36 is greater than the outer radius 82a where the inflection region 34 meets the main body region 36. A similar relationship can be found for the interior dimensions, although the number can vary depending on the thickness 14c of the barrel 14 within the insertion end 26.For example, inner diameters 80b and 82b correspond to outer diameters 80a and 82a, respectively, with the difference being due to thickness 14c. Those skilled in the art will appreciate that thickness 14c will vary in many embodiments.

[0049] In some embodiments, if the axial length 66 of the inflection region 34 does not exceed the diameter 86 at which the inflection curve 54 terminates, in view of the additional length 66 of the insertion end 26 due to the inflection region 34, which increases the inflection curve 54 beyond the base region 47 of the petal 45, a correlation can be drawn between (a) the axial length 62 of the insertion tip region 32, (b) the axial length 66 of the inflection region 34, and (c) the hypotenuse 88 of the inflection curve 54, which can also be discussed in the following equation:

[0050] The hypotenuse 88 of the inflection curved portion 54 > √((axial length of the insertion tip region) 2 + (axial length 62 of insertion tip region 32 + axial length 66 of inflection region 34) 2 )

[0051] For clarity, the above equation does not utilize the Pythagorean theorem, as it does not reflect the three sides of a right triangle. Rather, the above equation indicates that, in certain embodiments, the square of the hypotenuse 88 of the inflection curve 54 is greater than the sum of the squares of the axial lengths 62, 66 described above. In other words, the insertion end 26 is lengthened 62 through the inflection region 34 by a distance less than the diameter 86 of the barrel 14 where the inflection curve 54 terminates; therefore, what is normal is the hypotenuse 90 of the insertion tip region 32 (i.e., the hypotenuse 90 from the petal free end 46 to the termination 50 of the slit 48 between the petals 45). This concept can be used in both molded and unmolded states, as it relates to the external geometry 14b as well as the internal geometry 14b, as explained below. For example, diameter 86 is referred to as diameter 86a in the context of the exterior geometry and as diameter 86b in the context of interior geometry 14b; similarly, hypotenuses 88 and 90 are 88a and 88b, and 90a and / or 90b, for exterior geometry "a" and interior geometry "b." Similarly, lengths 62 and 64 of insertion tip region 32 are 62a and 64a, respectively, when associated with exterior geometry 14a, and 62b and 64b, respectively, when associated with exterior geometry 14b, in the formed and unformed states, respectively. Additionally, lengths 66 and 68 of inflection region 34 are 66a and 68a, respectively, when associated with exterior geometry 14a, and 66b and 68b, respectively, when associated with interior geometry 14b, in the formed and unformed states, respectively. Additionally, while inflection curve 54 is determined when in the formed state, inflection curve 54 also has an unformed length 68 that can be determined by geometric calculations of insertion end 26 in the formed state. Similarly, insertion tip region 32 has an unformed length 64.

[0052] The internal geometry 14b is particularly relevant to discharge efficiency. Internal geometry 14b focuses on the relationship between the inner diameter 80a of the barrel 14 where the slits 48 between the petals 45 terminate 50, and inner diameter 82a describes the inner diameter at the inflection region 34. Internal geometry relates to how either or both of the inner diameters 80b and 82b compare to the length 62 of the formed petals 45. To the extent that the length 62 between the free ends 46 of the petals 45 (as formed) at the inflection region 34 (as formed) is greater than the inner radius 82b or outer radius 82a where the inflection region 34 ends and the main body region 36 begins, a longer or more gradual taper is achieved that is more conducive to discharge efficiency. In some embodiments, the length between the inner surfaces of the free ends 46b of the petals 45 at the ends 50 of the slits 48 exceeds the inner radius 80b of the barrel 14 where the insertion tip region 32 meets the main body region 36. In some embodiments, the length between the inside of the petal free end 46b and where the inflection region 34 meets the main body region 36 exceeds the inner radius 82b where the inflection region 34 meets the main body region 36.

[0053] The inner hypotenuse 88b and / or 90b are particularly useful in that they characterize how well the pledget 22 nests within the insertion end region 26, resulting in improved ease of insertion. A pledget 22 shaped so that at least a portion of the pledget 22 intersects the inner hypotenuse 88b and / or 90b indicates that the pledget 22 supports at least a portion of the insertion tip end 26. In some embodiments, the pledget 22 intersects the hypotenuse 88 and / or 90 of the insertion tip region 26. In some embodiments, the pledget 26 intersects the hypotenuse 90 of the inflection curve. In yet other embodiments, the pledget 22 intersects both the hypotenuse 88 of the insertion tip region 26 and the hypotenuse 90 of the inflection curve 54. For simplicity, the interior geometry 14b is preferred, however, measurements can also be taken from the exterior geometry 14b if the thickness 14c is thin. In other words, the applicator 12 is generally a thin piece, and therefore, if the pledget 22 intersects the outer hypotenuse 88a or 90a, it is likely that the pledget will also intersect any such inner hypotenuse 88b or 90b. Furthermore, the hypotenuses 88 and / or 90 are calculated in the molded state. In some embodiments, when the pledget 22 is released, the pledget 22 supports at least the free end 46 of the petal 45. While some embodiments have a shape of the pledget 22 substantially similar to the insertion end region 26, some embodiments do not require insertion into the body or the like, but rather require a physical force to press down on the applicator 12 (i.e., at the insertion end region 26), thus pushing the insertion end 26 into contact with the pledget 22. Thus, so long as the shapes of the insertion end region 26 and the pledget 22 are somewhat similar to at least some of the features described throughout this disclosure, greater ease or comfort of insertion is achieved or improved.

[0054] The external geometry 14a, as it relates to the internal geometry 14b, also affects dispense efficiency. Thinner petals 45 generally deflect with less force than thicker petals 45, and therefore the relative thickness 14c of the petals 45 can affect dispense efficiency. Because it can be difficult to create very thin petals 45, portions of the petals 45 can be locally thinner than other portions of the petals 45 to provide improved dispense efficiency. These locally thin areas can provide an aesthetic appearance that indicates to the consumer that the applicator 12 has improved ease of insertion (i.e., dispense efficiency and / or insertion comfort).

[0055] The present disclosure further contemplates elongated petals 45. It has also been found that increasing the length 49 of the petals 45 also reduces the amount of force required to expel the pledget 22 from the barrel 14, thus improving expulsion efficiency. Note that in various embodiments, the petal length 49 is the same as either or both of the length 62 (or 64) of the insertion tip region 32 and the length 66 (or 68) of the inflection region 34. Similarly, as taught throughout this disclosure, the petal length 49a and petal length 49b relative to the exterior geometry 14a correspond to the interior geometry 14b. For example, consider the slit 48 in FIG. 18. As shown in FIG. 17, as the slit 48 extends further into the main body region 36 of the barrel 14, the expulsion force required to actuate the tampon applicator 12 is reduced.

[0056] Extending the slit 48 as suggested also changes the shape and taper rate of the petal 45. That is, the petal 45, which was largely semicircular or parabolic, now has a portion near the base region 47 that is largely linear. For example, FIGS. 17 and 18 each show a flat section of the petal 45 design; the petal 45 in FIG. 18 is almost entirely curved with no or only a few linear sections; and FIG. 17 shows a petal 45 with a curved region similar to that in FIG. 18, but the petal 45 in FIG. 17 has a longer linear section, as shown as the region between the two dashed lines 98 and 100. It should be understood that increasing the length 49 of the petal 45, even if achieved by extending the linear region, increases the taper rate of the insertion tip.

[0057] This disclosure further contemplates configurations of the insertion end 26 having various spacings between the petals 45. FIGS. 10-11 depict a front view of the insertion end 26 having four petals 45 separated by slits 48 running parallel to the longitudinal axis 11 of the tampon applicator 12. The slits 48 at the free ends 46 of the petal 45 region form an "X" shape. The forward-most end 44 (i.e., at the free ends of the petals 45) also includes an opening 30 that is much smaller than the diameter 92 of the main body region 36 of the barrel 14. As discussed throughout this disclosure, diameter 92a is the outer diameter (of the main body region 36), while diameter 92b is the inner diameter (of the main body region 36). The opening 30 further separates the free ends 46 of the petals 45. The opening 30 is indicated by the center portion of the "X" or the intersection of the two slanted lines of the "X." 12 is a schematic diagram of a front view of the applicator insertion end 26 of FIG. 10 , where the dotted line represents the inscribed circle 58 of the opening 30 as defined above, and the larger outer circle represents the inner diameter 92b of the barrel 14 where the barrel 14 meets the insertion end 26. The degree of closure is defined as the ratio of the diameter 60 of the opening 30 at the insertion end 26 to the inner diameter 92b of the barrel 14 where the insertion end 26 abuts the main body region 36 of the barrel 14.

[0058] The diameter of the closure (ie, insertion end opening 30) and its effect on ejection force is shown in Table 1 below. [Table 1]

[0059] Table 1 above shows the ability to change the ejection force by 1 Newton (3.6 ounces) by changing the closure diameter 30 by 0.76 mm (0.030 inches). In other words, increasing or decreasing the closure diameter 30 by 0.76 mm, respectively, can increase or decrease the ejection force by 1 Newton. Another way to explain the relationship between closure diameter 30 and ejection force is that by changing the closure diameter 30 by 1 mm (0.039 inches), the ejection force changes by 1.312 Newtons (4.719 ounces).

[0060] As noted above, enlarging the opening 30 in the insertion end 26 reduces the amount of force required to expel the pledget 22 from the barrel 14. This effect has been found to be relatively more pronounced in insertion ends 26 having a greater taper, such as the insertion end 26 shown in the schematic diagram of FIG. 7, than in insertion ends 26 that are blunt or more bulbous, such as the insertion end 26 shown in the schematic diagram of FIG. 6.

[0061] The length of the petals 45 also affects the ejection force, as shown in Table 2 below. [Table 2]

[0062] Table 1 above shows the ability to change the ejection force by 1 Newton (3.6 ounces) by changing the length 49 of the petal 45 by 1.33 mm (0.052 inches). In other words, increasing or decreasing the length 49 of the petal 45 by 1.33 mm increases or decreases the ejection force by 1 Newton, respectively. Another way to explain the relationship between the length 49 of the petal 45 and the ejection force is that by changing the length 49 of the petal 45 by 1 mm (0.039 inches), the ejection force changes by 0.75 Newtons (2.698 ounces).

[0063] The geometry of the gap 51 in the petal 45, as described by the petal slit 48 in the base region 47 of the petal 45, is also within the scope of this disclosure. A teardrop-shaped gap 51 improves ease of insertion. The radius of curvature 52 of the gap 51 is between about 0.028 inches and about 0.030 inches. The diameter of the gap 51 is between about 0.020 inches and about 0.056 inches. In some embodiments, the gap 51 between adjacent petals 45 is greater than about 0.005 inches.

[0064] The insertion end 26 has a radius of curvature 96 between about 0.200 inches and about 0.420 inches. In other embodiments, the insertion end 26 has a radius of curvature 96 greater than about 0.400 inches or greater than about 0.420 inches. In some embodiments, the insertion end 26 has a first radius of curvature 96a between about 0.202 inches and about 0.220 inches. In some embodiments, the insertion end 26 has a second radius of curvature 96b between about 0.336 inches and about 0.409 inches. In some embodiments, the insertion end 26 has a third radius of curvature 96c between about 0.373 inches and about 0.392 inches. In some embodiments, the insertion end 26 has a radius of curvature 96 between about 0.201 inches and about 0.399 inches.

[0065] The insertion end 26 of the present disclosure is at least ten percent (10%) of the overall length 70 of the molded applicator barrel 14. In some embodiments, the length 70 is between about 2.0 inches and about 3.5 inches, and more preferably between about 2.5 inches and about 3.0 inches. In some embodiments, the length is greater than about 2.0 inches or less than about 3.5 inches. In yet other embodiments, the length is between about 2.75 inches and about 3.0 inches. In some embodiments, the length of the insertion end 26 is at least fifteen percent (15%) of the overall length 70 of the molded applicator barrel 14. In yet other embodiments, the length of the insertion end 26 is at least twenty percent (20%) of the overall length 70 of the molded applicator barrel 14. As described throughout this disclosure, depending on the embodiment, recall the length of insertion end 26, length 62 or 64, respectively, of insertion tip region 32, and / or length 66 or 68, respectively, of inflection region 34, or both.

[0066] The length 72 of the main body region is at least 1.25 inches or up to about 2.0 inches, more preferably between about 1.25 inches and about 1.75 inches. The length 74 of the finger grip region 40 is at least about 0.5 inches or up to about 1.0 inch, more preferably between about 0.50 inches and about 0.75 inches. The length 76 of the reverse taper region 38 is at least 0.10 inches or up to about 0.5 inches, or more preferably between about 0.125 inches and about 0.4 inches.

[0067] The applicator 12 of the present disclosure can be modeled similarly to a modified cantilevered beam equation. Such a model, called the applicator deflection coefficient, relates the number of petals 22, Young's modulus, moment of inertia, deflection, petal 45 length 49, petal 45 width 43, petal 45 thickness 14c at the base region 47, barrel 14 diameter 78 at the slit end 50, and radius of curvature 52 of the gap 51 between adjacent petals 45 at the base region 47. The model was validated against currently known applicators, including the PLAYTEX SPORT applicator and the PLAYTEX GENTLE GLIDE applicator. Samples of the presently disclosed invention were also modeled. The model provides a basis for modifying aspects of the insertion end 26, insertion tip region 32, inflection region 34, and / or petal 45 measurements to promote improved tampon assembly 10 performance.

[0068] The cantilever beam equations mentioned above are defined both in terms of petal length and in terms of petal thickness as follows:

[0069] Cantilever-Beam Equation - Petal Thickness Definition: F pb = Pedal bending force F e = release force N = number of petals E = Young's modulus of elasticity I = second moment of inertia L f = Molded petal length δ = deflection b = width of petal at base t = petal thickness d barrel = outer diameter of barrel at base of petal d tear = diameter of the "teardrop" inside the petal

[0070] Bending force for a single petal:

number

[0071] Emission force for multiple petals:

number

[0072] Converting Ejection Force to Ounces

number

[0073] E has units of psi and d barrel , d tear , t, L f and δ are assumed to have units of inches.

[0074] Cantilever-Beam Equation - Petal Thickness Definition: F e = release force N = number of petals E = Young's modulus of elasticity I = second inertial motion L f = Molded petal length δ = deflection b = width of petal at base t = petal thickness d barrel = outer diameter of barrel at base of petal d tear = diameter of the "teardrop" inside the petal t e = effective thickness t max = Maximum petal thickness t min = minimum petal thickness α = percentage of "thick" petal area (0<α<1) β = percentage of "thin" petal area (0<β<1) n = number of regions of thickness "i" t i = thickness "i" ε i = t across the petali Percentage of

[0075] Emission force for multiple petals:

number

[0076] Effective thickness as a function of two different thicknesses: t e =αt max +βt min

[0077] Effective thickness as a function of thickness series:

number

[0078] Emission force based on petals with various thicknesses:

number

[0079] Ejection force for petals of various thicknesses in ounces:

number

[0080] E has units of psi and d barrel , d tear , t, L f and δ are assumed to have units of inches.

[0081] Many tampon applicators 12 are made from plastic materials and therefore have a modulus of stiffness that is typically between about 27,000 psi and about 70,000 psi.

[0082] 19-20 show angled views of the barrel 14 highlighting the width 43 of the petals 45 in their molded state, as well as the gaps 51 and slits 48 in the petals 45. The width 43 of the petals 45 (as well as the slits 48 or gaps 51) can vary along the length 49 of the petals 45, but is generally determined by taking the circumference of the applicator around a portion of the barrel 14 at the base region 47 of the petals 45, subtracting out the diameter of the slits 48 or gaps 51, and then dividing by the number of petals. The width 43 of the petals 45 of the present disclosure varies from about 0.14 inches to about 0.68 inches. In some embodiments, the width 43 of the petals 45 is between about 0.20 inches and about 0.45 inches, and in yet other embodiments, between about 0.24 inches and about 0.42 inches. In yet other embodiments, the width 43 of the petals 45 is between about 0.25 inches and about 0.40 inches.

[0083] Figure 3 below illustrates some embodiments using theoretical and actual measurements. [Table 3]

[0084] This model is based on a well-known semicircular insertion tip, such as that of the PLAYTEX GENTLE GLIDE. Because it is based on a theoretical model, the theoretical numbers for the PLAYTEX GENTLE GLIDE deviate from the actual numbers. Nevertheless, as shown by Table 3 above, the theoretical model shows how petal gap 51 and petal length 49 can affect ejection force. Table 3 is illustrative and not limiting.

[0085] It can also be appreciated that other modifications to the shape of the curved portion of the petal 22, such as a more rounded end, or differences in slope along a portion of the curve or along the entire curve, can also affect ejection force or insertion comfort. Additionally, the degree of inward curl toward the longitudinal axis 11 of the barrel 14 can affect these characteristics.

[0086] The tampon applicator 12 of the present disclosure also has certain performance characteristics, such as requiring an ejection force of about 5 oz to about 25 oz to expel the pledget 22 from the barrel 14 of the tampon applicator 12, and typically requiring an ejection force of less than 25 oz, e.g., 20 oz or less, and often requiring an ejection force of 15 oz or less, to expel the pledget 22. Thus, in various embodiments, the tampon applicator 12 requires an ejection force of about 8 oz to about 20 oz, i.e., 2.2 N to 5.6 N, e.g., about 10 oz to 20 oz, i.e., 2.8 N to 5.8 N, about 10 oz to 15 oz, i.e., 2.8 N to 4.2 N, or 10 oz to 12 oz, i.e., 2.8 N to 3.3 N, to expel the pledget 22.

[0087] Embodiments of the present disclosure provide a tampon applicator 12 that incorporates one or more of these discoveries. A general embodiment of the present disclosure provides a tampon applicator 12 that includes a plunger 16 and a barrel 14, the barrel 14 being generally tubular in shape and including a generally circular or oval hollow interior cavity 15, a main body region 36 having a forward-most end 44 that defines a tapered insertion end 26 formed by three to eight petals 45, the insertion end 26 terminating in an opening 30 defined by the free ends 46 of the petals 45. The insertion end 26 has a generally circular or oval shape similar to the shape of the hollow interior cavity 15 of the main body region 36 where the insertion end 26 is adjacent the main body region 36, a rearward-most end 84 opposite the forward-most end 44, the rearward-most end 84 having an opening 31 through which the plunger 16 is slidably disposed, the insertion end 26 has a taper ratio as defined above of from about 1.3 to about 3.5, the opening 30 of the insertion end 26 has a degree of closure as defined above of from about 0.1 to about 0.3, and the tampon applicator 12 requires an ejection force of from about 5 oz to about 25 oz to eject the absorbent pledget 22.

[0088] In most embodiments, barrel 14 has a circular interior, i.e., the cross section of main body region 36 of barrel 14 defines a closed circle, and opening 30 in insertion end 26 has an inscribed circle 60. It should be understood that the actual shape of opening 30 in insertion end 26 is not that of a simple circle, and the shape of petal free ends 46 and the size of slits 48 defining petals 45 result in an irregularly shaped opening 30. Circular, as used in connection with opening 30 in insertion end 26, means that the outline of the regular curve defined by free ends 46 of petals 45 is, in this case, circular, rather than elliptical.

[0089] In many embodiments, insertion end 26 is formed by three to six or three to five petals 45 , for example, three, four, or five petals 45 .

[0090] The expulsion force of the tampon applicator 12 of the present disclosure does not exceed 25 oz. In many embodiments, the required expulsion force is from about 8 oz to about 20 oz. In many preferred embodiments, the required expulsion force is from about 10 oz to about 20 oz, or from about 10 oz to about 15 oz, e.g., from about 10 oz to about 12 oz.

[0091] In many embodiments, the tampon applicator 12 has a taper ratio of from about 1.3 to about 2.5, e.g., at least 1.5, 1.6, or 1.7 to about 2.3, 2.2, or 2.0, and in many embodiments, the tampon applicator 12 has a degree of closure of from about 0.1 to about 0.25, from about 0.1 to about 0.20, e.g., from about 0.12 to about 2.0 or from about 0.14 to about 0.25.

[0092] While the tampon applicator 12 is related to the outer dimension 14a of the applicator 12, the degree of closure is related to the inner dimension 14b. The direct relationship between taper and degree of closure is due to the wall thickness 14c of the barrel 14 where the main body region 36 abuts the insertion end 26, and the thickness 14c of the petal 45 at the petal's free end 46. The wall thicknesses 14c of the barrel 14 and petals 45 of the present disclosure are generally those experienced in the art and may vary somewhat.

[0093] As discussed above, in view of the reduced ejection force due to this reconfiguration of the insertion end 26, it may be possible to create the applicator 12 with somewhat thicker petals 45, which may prevent undesired deformation of the insertion end 26. For example, in many embodiments, the petals 45 have a thickness in the ranges found in U.S. Patent No. 6,222,626,628, e.g., from about 0.004 inches to about 0.022 inches, from about 0.008 inches to about 0.018 inches, or from about 0.009 inches to about 0.013 inches, although in many embodiments the thickness of the petals 45 may be at the higher end of such ranges. In some embodiments, the petals 45 may be thicker than those in U.S. Patent No. 6,222,626,626, e.g., 0.025 inches, 0.03 inches, or 0.035 inches.

[0094] Generally, the petals 45 have a high degree of thickness uniformity. Uniformity of the petal 45 thickness 14c across the entire area of ​​each petal 45 is advantageous for several reasons. First, uniformity of the petal 45 thickness 14c can lead to processing efficiencies in creating the applicator 12. Second, uniform thickness 14c ensures that each petal 45 functions properly both during storage and transportation of the applicator 12, and more importantly, during use by a woman. Additionally, uniform petals 45 are more aesthetically pleasing to the consumer.

[0095] In many embodiments of the present disclosure, the thickness 14c measured at any point on a given petal 45 does not vary by more than about 25% over the entire area of ​​the petal 45, often the thickness 14c does not vary by more than about 10% over the entire area of ​​the petal, and in some embodiments the thickness 14c does not vary by more than about 2% over the entire area of ​​the petal 45.

[0096] The barrel 14 and plunger 16 can be made from the same or different materials, including embodiments having a two-piece plunger 16 with an inner plunger 18 and an outer plunger 20. For example, the plunger 16 and / or barrel 14 of the tampon applicator 12 can be made from cardboard, but in many embodiments, at least a portion of the tampon applicator 12, e.g., the barrel, or the entire applicator, is made from a composition including a thermoplastic polymer, an elastomeric polymer, or a blend of a thermoplastic polymer and an elastomeric polymer. For example, the tampon applicator can be made from a polymer composition including one or more synthetic polymers and / or polyolefin polymers or copolymers, polyesters, polyimides, polystyrene, polyvinyl chloride, polyacrylates, polymethacrylic acid, polyvinyl alcohol, polylactic acid, or natural materials such as moldable starch. In most cases, the polymer comprises a thermoplastic polymer, a blend of a thermoplastic polymer and an elastomeric polymer, for example, the polymer often comprises polyethylene, low density polyethylene, high density polyethylene, near low density polyethylene, polypropylene, or a copolymer of ethylene, styrene, isoprene, or butadiene monomers. In many embodiments, the organic polymer comprises low density polyethylene, high density polyethylene, or a blend of low density polyethylene and high density polyethylene.

[0097] In some embodiments, the organic polymer comprises a blend of polyethylene, such as low-density polyethylene, and a thermoplastic elastomer. For example, the organic polymer may comprise a blend of about 50% to about 90%, e.g., 80%, by weight of low-density polyethylene and about 50% to about 10%, e.g., 20%, by weight of a thermoplastic elastomer, based on the total weight of the composition. Useful thermoplastic elastomers are triblock (terpolymer) polymers having monomers in an ABA configuration, where monomer B is not the same as monomer A. Typically, the blocks comprise styrene, butadiene, or isoprene monomers. Other classes of useful thermoplastic elastomers include, for example, thermoplastic polyurethane elastomers.

[0098] When the tampon applicator 12 comprises a thermoplastic or elastomeric polymer composition, the composition also generally includes one or more of a variety of common additives, such as processing aids, stabilizers, lubricants, colorants, etc. For example, the polymer composition may include processing aids such as one or more plasticizers, compatibilizers, flow control agents, antioxidants, antistatic agents, fillers, reinforcing agents, surfactants, heat stabilizers, impact modifiers, stearate salts, lubricants, flame retardants, biocides, antiozonants, foaming agents, defoamers, etc. To retain or maintain adequate softness and / or lubricity, the composition generally includes at least 0.05 of a lubricant, for example, a fatty acid amide such as erucamide, oleamide, stearamide, stearyl erucamide, bis-erucamide, ethylene bis-stearamide, ethylene bis-oleamide.

[0099] Some embodiments of the present disclosure provide a tampon assembly 10 including a tampon applicator 12 of the present disclosure and an absorbent tampon pledget 22 housed within the barrel 14 (prior to expulsion from the barrel 14 when used within a user's body). The pledget 22 can have a shape corresponding to the interior geometric shape 14b of the main body region 36 of the barrel 12, or at least a portion of the pledget 22 can be shaped to correspond to at least a portion of the interior geometric shape 14b of the insertion end 26 as in U.S. Patent No. 6,279,999. Materials suitable for forming the pledget 22 include, for example, cellulose derivatives, rayon, cotton, pulp, superabsorbent materials such as Oasis, absorbent foams such as hydrophilic polyurethane foam, or any combination thereof.

[0100] The reconfigured insertion end 26 of the present disclosure further attempts to find the proper balance between ejection force and stability of the petal 45, particularly at the petal free end 46. No particular limitations are placed on the main body region 36 of the barrel 14 or plunger 16, each of which can include any of a variety of features known in the art.

[0101] As used herein, the terms "a" or "an" are used to include one or more than one, as is common in patent documents. As used herein, the term "or" is used to refer to a non-exclusive context, unless otherwise specified. It should be understood that the above description is intended to be illustrative, and not limiting. For example, the above-described embodiments (and / or aspects thereof) can be used in combination with each other. Many other embodiments will become apparent to those skilled in the art upon reviewing the above description. The scope of the present disclosure should therefore be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, terms such as "including" and "in which" are used as the plain-English equivalents of the respective terms "comprising" and "wherein." Moreover, in the following claims, the terms "first," "second," and "third," etc., when inclusive, are used merely as labels and are not intended to impose numerical requirements on their objects. In the Detailed Description provided above, various features may be grouped together to streamline the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Accordingly, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.

Claims

1. A barrel 14 having a straight central longitudinal axis 11, said barrel 14 comprising: an insertion tip region 32 having between three and eight petals 45, each of said petals 45 having a free end 46 coincident with the forward-most end 44 of the inflection curve 54, each of said petals 45 separated from one another by a plurality of slits 48, said insertion tip region 32 having a shaped insertion tip region length 62 defined from said free ends 46 of said petals 45 where said slits 48 between said petals 45 terminate 50, said insertion tip region 32 defining an insertion tip region radius 80; an inflection region 34 adjacent to or at least partially overlapping the insertion tip region 32, defining a shaped inflection region length 66 and having an inflection region radius 82; a main body region 36 adjacent said inflection region 34; a gripping region (40) adjacent said main body region (36); a plunger 16 telescopically engaged with the barrel 14; the inflection region radius 82 is located where the inflection region 34 intersects with the main body region 36; The shaped insertion tip region length 66 is different from the shaped insertion tip region length 62; an insertion taper ratio is the ratio of the shaped insertion tip region length 62 to the insertion tip region radius 80, the insertion taper ratio being greater than 1; an inflection taper ratio is the ratio of (a) the sum of the shaped insertion tip region length 62 and the shaped inflection region length 66 to (b) the larger of the insertion tip region radius 80 and the inflection region radius 82, wherein the inflection taper ratio is greater than 1; The tampon applicator (12) is characterized in that said insertion tip region (31), said inflection region (34), said main body region (36), and said grip region (40) are coaxial about said straight central longitudinal axis (11).

2. 2. The tampon applicator of claim 1, wherein the inflection region is adjacent to the insertion tip, and the sum of the insertion tip length and the inflection region length is greater than the insertion tip length.

3. 2. The tampon applicator of claim 1, wherein the inflection region overlaps the insertion tip region, and the sum of the insertion tip length and the inflection region length is less than the insertion tip length.

4. 2. The tampon applicator of claim 1, wherein the length of said inflection region is less than said inflection region radius.

5. 2. The tampon applicator of claim 1, wherein said sum of said insertion tip length (62) and said inflection region length (66) is at least about 10% of a barrel length (70) of said barrel (14).

6. A tampon applicator 12 comprising: an insertion tip region 32 having between three and eight petals 45, each of said petals 45 having a free end 46 defining an inscribed polygon 56, said petals 45 being separated from one another by a plurality of slits 48; a main body region (36) adjacent the insertion tip region (32) and having a main body diameter (70) beginning at and defined by where the slits (48) between the petals (45) terminate (50); a gripping region 40 adjacent the main body region 36; a barrel 14 including a plunger 16 telescopically engaged with the barrel 14; Equipped with an inscribed circle 58 is defined within the inscribed polygon 56 and defines an inscribed circle diameter 60 between about 0.075 inches and about 0.150 inches; The tampon applicator (12), wherein the degree of closure between said inscribed circle (58) and the beginning of said main body diameter (92) is between about 0.1 and about 0.

3.

7. 7. The tampon applicator (12) of claim 6, wherein said insertion tip region (32) is hemispherical.

8. 7. The tampon applicator of claim 6, wherein said insertion tip region is tapered and other than hemispherical.

9. A tampon applicator 12 comprising: has a total barrel length 70 of at least 2.0 inches; and an insertion end region having an insertion tip length, said insertion tip defining a forward-most end 44 of said barrel 14, said insertion tip region 32 having between three and eight petals 45; an inflection region 34 having a curved shape and an inflection region length 66 adjacent to and / or overlapping the insertion tip region 32; a main body region 36 adjacent said inflection region 34 and having a main body region length 72 of at least 1.25 inches; a gripping area 40 having a gripping area length 74 of at least 0.5 inches and defining a rearward-most end 84 of said barrel 14; a barrel 14 including The insertion tip region length 62 is different from the inflection region length 66, the sum of the insertion tip region length 62 and the inflection region length 66 is at least about 0.4 inches; the main body region 36 is substantially straight, has a linear taper, or has a different curvature than the inflection region 34; 1. A tampon applicator (12), wherein (a) the sum of said insertion tip region length (62) and said inflection region length (66) divided by (b) said total barrel length (70) is (c) at least about 0.

2.

10. 11. The tampon applicator (12) of claim 10, wherein each of said petals (45) has a petal width (43) between about 0.14 inches and 0.68 inches.

11. 10. The tampon applicator (12) of claim 9, wherein said tampon applicator (12) has an ejection force of between about 7.5 oz and about 20 oz.

12. 1. An insertion end (26) for a tampon applicator (12), said insertion end (26) having between three and eight petals (45) separated by slits (48), said petals (45) having free ends (46) defining a forward-most end (44) of said insertion end (26), said insertion end (26) having a rearward-most end (84) defined by terminal ends (50) of said slits (48), said insertion end (26) having a radius of curvature (96) that generally defines an exterior geometry (14a) of said insertion end (26) between said forward-most end (44) and said rearward-most end (84) of greater than about 0.400 inches, said slits (48) being precisely shaped, said terminal ends (50) of said slits (48) forming a teardrop shape having a radius of curvature (52) of between about 0.028 inches and about 0.030 inches.

13. 14. The insertion end (26) of claim 13, wherein each of said petals (45) has a petal width (43) between about 0.24 inches and 0.42 inches.

14. 14. The insertion end 26 of claim 13, wherein the free end 46 of each of the petals 45 defines an inscribed polygon 56, the inscribed polygon 56 defining an inscribed circle 58 having a diameter 60 between about 0.075 inches and about 0.150 inches.

15. 15. The insertion end (26) of claim 14, wherein the degree of closure between the inscribed circle (58) and the terminal end (50) of the slit (48) of the petal (45) is between about 0.1 and about 0.

3.

16. A tampon applicator 12 comprising: having a straight central longitudinal axis 11; and an insertion tip region 32 having between three and eight petals 45, each of said petals 45 having a free end 46 coincident with the forward-most end 44 of the inflection curve 54, each of said petals 45 separated from one another by a plurality of slits 48, said insertion tip region 32 having a shaped insertion tip region length 62 defined from said free ends 46 of said petals 45 where said slits 48 between said petals 45 terminate 50, said insertion tip region 32 defining an insertion tip region radius 80; an inflection region 34 adjacent to or at least partially overlapping the insertion tip region 32, defining a shaped inflection region length 66 and having an inflection region radius 82; a main body region 36 adjacent said inflection region 34; a gripping region 40 adjacent the main body region 36; a barrel 14 including a plunger 16 telescopically engaged with the barrel 14; Equipped with the inflection region radius 82 is located where the inflection region 34 intersects with the main body region 36; The shaped insertion tip region length 66 is different from the shaped insertion tip region length 62; an insertion taper ratio is the ratio of the shaped insertion tip region length 62 to the insertion tip region radius 80, the insertion taper ratio being greater than 1; an inflection taper ratio is the ratio of (a) the sum of the shaped insertion tip length 62 and the shaped inflection region length 66 to (b) the larger of the insertion tip region radius 80 and the inflection region radius 82, wherein the inflection taper ratio is greater than 1; 16. The tampon applicator (12) of any one of claims 1 to 15, wherein the insertion tip region (31), the inflection region (34), the main body region (36), and the grip region (40) are coaxial about the straight central longitudinal axis (11).

17. 17. The tampon applicator (12) of any one of claims 1 to 16, wherein the inflection region (34) is adjacent to the insertion tip (32), and the sum of the insertion tip length (62) and the inflection region length (66) is greater than the insertion tip length (62).

18. 18. The tampon applicator (12) of any one of claims 1 to 17, wherein the inflection region (34) overlaps the insertion tip region (32), and the sum of the insertion tip length (62) and the inflection region length (66) is less than the insertion tip length (62).

19. 19. The tampon applicator (12) of any of claims 1-18, wherein the length of said inflection region (34) is less than said inflection region radius (82).

20. 20. The tampon applicator (12) of any one of claims 1 to 19, wherein the sum of the insertion tip length (62) and the inflection region length (66) is at least about 10% of the barrel length (70) of the barrel (14).

21. A tampon applicator 12 comprising: an insertion tip region 32 having between three and eight petals 45, each of said petals 45 having a free end 46 defining an inscribed polygon 56, said petals 45 being separated from one another by a plurality of slits 48; a main body region (36) adjacent the insertion tip region (32) and having a main body diameter (70) beginning at and defined by where the slits (48) between the petals (45) terminate (50); a gripping region 40 adjacent the main body region 36; a barrel 14 including a plunger 16 telescopically engaged with the barrel 14; Equipped with an inscribed circle 58 is defined within the inscribed polygon 56 and defines an inscribed circle diameter 60 between about 0.075 inches and about 0.150 inches; 21. The tampon applicator (12) of any of claims 1-20, wherein the degree of closure between said inscribed circle (58) and the beginning of said main body diameter (92) is between about 0.1 and about 0.

3.

22. 22. The tampon applicator (12) of any of claims 1-21, wherein said insertion tip region (32) is hemispherical.

23. 23. The tampon applicator (12) of any of claims 1-22, wherein said insertion tip region (32) is tapered and other than hemispherical.

24. A tampon applicator 12 comprising: has a total barrel length 70 of at least 2.0 inches; and an insertion end region having an insertion tip length, said insertion tip defining a forward-most end 44 of said barrel 14, said insertion tip region 32 having between three and eight petals 45; an inflection region 34 having a curved shape and an inflection region length 66 adjacent to and / or overlapping the insertion tip region 32; a main body region 36 adjacent said inflection region 34 and having a main body region length 72 of at least 1.25 inches; a gripping area 40 having a gripping area length 74 of at least 0.5 inches and defining a rearward-most end 84 of said barrel 14; a barrel 14 including The insertion tip region length 62 is different from the inflection region length 66, the sum of the insertion tip region length 62 and the inflection region length 66 is at least 0.4 inches; the main body region 36 is substantially straight, has a linear taper, or has a different curvature than the inflection region 34; 24. The tampon applicator (12) of any of claims 1 to 23, wherein (a) the sum of the insertion tip region length (62) and the inflection region length (66) divided by (b) the total barrel length (70) is (c) at least about 0.

2.

25. 25. The tampon applicator (12) of any of claims 1-24, wherein each of said petals (45) has a petal width (43) of between about 0.14 inches and 0.68 inches.

26. 26. The tampon applicator (12) of any of claims 1-25, wherein said tampon applicator (12) has an ejection force of between about 7.5 oz and about 20 oz.

27. 27. The insertion end 26 of any one of claims 1 to 26, characterized in that the insertion end 26 for a tampon applicator 12 has between three and eight petals 45 separated by slits 48, the petals 45 having free ends 46 defining a forward-most end 44 of the insertion end 26, the insertion end 26 having a rearward-most end 84 defined by terminal ends 50 of the slits 48, the insertion end 26 having a radius of curvature 96 that generally defines an exterior geometric shape 14a of the insertion end 26 between the forward-most end 44 and the rearward-most end 84 of greater than about 0.400 inches, the slits 48 being precisely shaped, the terminal ends 50 of the slits 48 forming a teardrop shape with a radius of curvature 52 of between about 0.028 inches and about 0.030 inches.

28. 28. The insertion end 26 of any of claims 1-27, wherein each of the petals 45 has a petal width 43 between about 0.24 inches and 0.42 inches.

29. 29. An insertion end 26 as described in any one of claims 1 to 28, wherein the free end 46 of each of the petals 45 defines an inscribed polygon 56, the inscribed polygon 56 defining an inscribed circle 58 having a diameter 60 between about 0.075 inches and about 0.150 inches.

30. An insertion end (26) according to any one of claims 1 to 29, characterized in that the degree of closure between the inscribed circle (58) and the terminal end (50) of the slit (48) of the petal (45) is between about 0.1 and about 0.3.

Images