Radial Compression Tampon Molding for Density Uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tampon manufacturing processes face issues with high drag forces during molding, leading to uneven density profiles, surface imperfections, and difficulties in product removal, which affect the quality and efficiency of tampon production.
Innovation Solution
A method and apparatus that utilize a compression/stabilization mold with a transfer member to laterally compress the tampon pledget, eliminating the axial compression stage and enabling improved surface texture and density consistency, while also facilitating easier mold opening and product release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If axial compression is used to form tampons in conventional molds, then the tampons can be formed with desired shape, but high drag forces are created causing uneven density profiles
Solution Approach 1:
The patent transitions from axial compression (one-dimensional force application along the length of the tampon) to radial compression (force application from the sides outward). This dimensional change in the compression direction eliminates the dragging effect on the fibrous material while still achieving the desired tampon shape and consistent density throughout the product.
2Stress or pressure
If conventional molds are used with high drag forces, then tampons can be compressed, but surface imperfections and texturing issues occur
Solution Approach 1:
By applying compression forces radially from the sides rather than axially from the ends, the patent eliminates the dragging effect that causes surface imperfections. This allows the fibrous material to be compressed uniformly without being pulled through the mold, preserving surface smoothness and enabling proper formation of surface textures and patterns.
3Shape
If conventional molds are used for shaped and textured tampons, then the desired shape and texturing can be formed, but product removal becomes difficult
Solution Approach 1:
The radial compression approach creates a different stress distribution and bonding pattern between the tampon and mold compared to axial compression. This allows the tampon to be formed with complex shapes and textures while reducing the adhesion forces that make removal difficult, enabling easier ejection from the mold after compression.
4Shape
If fins or impact features are used to mold shaped tampons, then the desired shape and texturing can be achieved, but inconsistencies in density profile are created
Solution Approach 1:
By applying compression forces uniformly from the radial direction rather than using impact features from the axial direction, the patent achieves consistent density distribution throughout the tampon. This uniform radial compression eliminates the localized density variations and inconsistencies that result from using fins or impact features during molding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in tampons with improved surface smoothness, consistent density profiles, and enhanced re-expansion abilities, reducing manufacturing delays and costs by minimizing high drag forces and inconsistencies.
Implementation Method 1
laterally compressing the tampon pledget in the compression/stabilization mold by closing the compression/stabilization mold
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for making a tampon including providing a tampon pledget, and providing a compression/stabilization mold. The method includes moving the tampon pledget into the compression/stabilization mold via a transfer member, wherein the compression/stabilization mold is in an open position, and laterally compressing the tampon pledget in the compression/stabilization mold by closing the compression/stabilization mold to form a stabilized tampon. An apparatus for making a tampon and a tampon made by the method are also disclosed.