Tampon Applicator Plunger Flare Assembly via Elastic Deformation
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Solution Overview
Problem
The existing methods for assembling tampon applicators with flared ends are inefficient, requiring separate post-production operations which increase costs and complexity.
Innovation Solution
A method involving a barrel with internal ridges forming a guide channel and a plunger with flares, where the flare is deformed while passing through the channel and then reestablished, allowing for efficient assembly with the flare diameter being at least 15% larger than the guide channel diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flared ends are formed in a separate post-production operation, then the assembly process is simpler, but the manufacturing efficiency decreases and quality consistency is compromised
Solution Approach 1:
The patent combines the flare formation operation with the molding process by integrating a forming section into the mold cavity. This allows the plunger flare to be formed during the molding operation itself, eliminating the need for separate post-production flare formation steps and thereby improving manufacturing efficiency while maintaining assembly simplicity.
Solution Approach 2:
The flare is formed during the molding process before assembly occurs. By preliminarily forming the flare shape as part of the molding operation, the subsequent assembly process becomes more efficient and consistent, as the flare is already properly shaped and positioned for engagement with the barrel.
2Ease of manufacture
If flared ends are formed in a separate post-production operation, then the molding process is simpler, but the quality consistency of flare formation deteriorates
Solution Approach 1:
The forming section is integrated into the mold cavity, combining the flare formation with the molding process. This ensures that the flare is formed under the same controlled molding conditions as the rest of the plunger, resulting in consistent quality and precise dimensional control without requiring separate post-production operations.
Solution Approach 2:
The forming section utilizes the molding process itself to create the flare shape. The material is shaped into the flare configuration during injection or compression molding, allowing the molding process to serve the dual purpose of creating the plunger body and forming the flare, thereby ensuring quality consistency.
3Ease of operation
If the flare diameter is significantly larger than the guide channel diameter, then the user comfort and control are improved, but the assembly difficulty increases
Solution Approach 1:
The forming section is designed with specific geometric parameters that allow the large-diameter flare to be formed during molding. By optimizing the forming section dimensions, material flow, and molding parameters, the patent enables assembly of plungers with large flares (improving user comfort) while maintaining manageable assembly complexity through proper design of the forming geometry.
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
This method simplifies the assembly process, reduces production costs, and enhances the structural integrity of the tampon applicator by ensuring a secure and comfortable fit during use.
Implementation Method 1
deforming the flare while moving the flare through the guide channel, and reestablishing the flare after the flare exits the guide channel
Data Source
AI summary
A method of assembling a tampon applicator includes providing a barrel with internal ridges that define a guide channel having an effective diameter. The method includes providing a plunger that has a finger flare with a circular shape and a flare diameter that is at least 15% larger than the effective diameter of the guide channel. The method includes assembling the plunger and the barrel by pushing the finger flare into the guide channel and deforming the finger flare into a non-circular shape while moving the finger flare through the guide channel. The method includes moving the finger flare out of the plunger end of the barrel and reestablishing the circular shape of the finger flare.