Tampon Pledget Fiber Layout for Bypass Leakage Protection

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Solution Overview

Problem

Current tampon pledgets suffer from bypass leakage due to improper placement and suboptimal expansion, leading to premature leakage and difficulty in use with conventional applicators.

Innovation Solution

A tampon pledget design featuring specific pad lay-up ratios and fiber weight distributions across its length and width, enhancing absorption and expansion capabilities while maintaining applicator compatibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a tampon pledget with pre-expanded shape is used, then bypass leakage protection is improved, but device complexity and difficulty of use increase due to applicator deformation

Engineering Contradiction:

Improvebypass leakage protectionVSAvoidapplicator use difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The pledget is pre-formed into a compressed cylindrical shape that fits within the applicator barrel, allowing it to be inserted and deployed without deforming the applicator. The pledget then expands to its functional shape after insertion, providing bypass leakage protection while maintaining ease of use.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pledget undergoes a parameter change from a compressed state (for storage and insertion) to an expanded state (for function). This allows the pledget to fit within the applicator during use while providing the necessary shape for bypass leakage protection when deployed.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a tampon pledget with pre-expanded shape is used, then bypass leakage protection is improved, but device complexity increases due to additional forces on applicator walls

Engineering Contradiction:

Improvebypass leakage protectionVSAvoidapplicator barrel stress

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

3Productivity

If tampon pledget expansion is optimized, then absorption efficiency is improved, but bypass leakage protection worsens due to improper placement

Engineering Contradiction:

Improveabsorption efficiencyVSAvoidbypass leakage protection

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The pledget features a layered fiber construction with different fiber types and weights in different regions. The base portion has higher fiber weight and specific fiber composition to provide structural support and prevent bypass leakage, while the upper portions have optimized fiber distribution for maximum absorption efficiency.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The pledget uses a composite fiber construction combining different fiber types (cellulosic, rayon, superabsorbent polymers) with varying weights and distributions. This composite structure provides both the structural integrity needed for proper placement and the absorption capacity for high productivity.

Inventive Principle:

Principle #40Composite materials

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 design provides increased bypass leakage protection and rapid expansion, improving absorption efficiency and ease of use without requiring applicator modifications.

Implementation Method 1

tampon pledget that exhibits increased bypass leakage prevention... increased absorption potential at a base of the pledget

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

tampon pledget expansion is not optimal... increased expansion potential at the base of the pledget

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS12558269B2Tampon pledget for increased bypass leakage protection

Publication Date: 2026.02.24 EDGEWELL PERSONAL CARE BRANDS LLC

AI summary

There is provided a tampon pledget that includes one or more enhanced features that result in the pledget exhibiting increased bypass leakage prevention. These enhanced features may include, but are not limited to, geometry, absorption, and any combinations thereof. There is also provided one or more methods for constructing a tampon pledget having increased bypass leakage protection.