U.S. patent number 3,695,270 [Application Number 05/005,080] was granted by the patent office on 1972-10-03 for sanitary tampon.
This patent grant is currently assigned to International Playtex Corporation. Invention is credited to Zdenek Denny Dostal.
United States Patent |
3,695,270 |
Dostal |
October 3, 1972 |
SANITARY TAMPON
Abstract
An absorbent material and method of constructing such material
is disclosed. The absorbent material includes at least two united
constituents, one of which contains filaments with a portion of
such filaments transferred through openings in the other
constituent. The transference may be effected through the use of
transfer needles, which not only transfers filaments but
additionally provides the openings through which the filaments
extend. The absorbent material is particularly adapted for use in a
tampon or other other catamenial device. Other uses, such as in
disposable diapers or in other products where a relatively high
degree of absorbency in a relatively economical product is
desirable are also contemplated.
Inventors: |
Dostal; Zdenek Denny (Dover,
DE) |
Assignee: |
International Playtex
Corporation (New York, NY)
|
Family
ID: |
21714073 |
Appl.
No.: |
05/005,080 |
Filed: |
January 22, 1970 |
Current U.S.
Class: |
604/375;
604/385.18; 28/107; 28/118; 264/273; 604/383; 604/904 |
Current CPC
Class: |
A61F
13/2071 (20130101); A61F 13/53708 (20130101); A61F
13/538 (20130101); A61F 13/539 (20130101); A61F
13/53747 (20130101); A61F 13/2045 (20130101); A61F
13/2048 (20130101); A61F 2013/53445 (20130101); A61F
13/534 (20130101); Y10S 604/904 (20130101); A61F
2013/53966 (20130101); A61F 13/511 (20130101); A61F
2013/53908 (20130101); A61F 2013/8488 (20130101); A61F
2013/582 (20130101); A61F 13/202 (20130101); A61F
2013/51409 (20130101); A61F 13/58 (20130101) |
Current International
Class: |
A61F
13/20 (20060101); A61F 13/15 (20060101); A61F
13/56 (20060101); A61f 013/20 () |
Field of
Search: |
;128/156,284,287,290,296
;19/144.5,145 ;161/80,159 ;264/271,273 ;28/72.2R |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Rosenbaum; Charles F.
Claims
Having thus described certain forms of the invention in some
detail, what is claimed is:
1. A tampon comprising at least two constituent absorbent layers,
one of said layers having absorbent filaments, the other of said
absorbent layers having plurality of openings therethrough; a
portion of said absorbent filaments extending through the openings
in said other layer to form an integrated absorbent composite; said
absorbent composite oriented in said tampon whereby the major
portion of said openings having filaments extending therethrough
extend in a direction transverse to the body of said tampon.
2. A tampon comprising, a first strip of an absorbent composite, a
second strip of an absorbent composite, each of said strips
including superimposed layers of absorbent rayon and absorbent
crepe paper; said rayon layer having a plurality of filaments; said
crepe paper having a plurality of openings; said rayon and paper
layers united such that a portion of the filaments of said rayon
layer extend through the openings in said paper layers to form an
integrated composite; said first and second strips of absorbent
composite in superimposed relationship and formed into a
substantially cylindrical compressed body such that the major
portion of said opening in said paper layers extend in a direction
transverse to said cylindrical body.
3. The tampon as claimed in claim 2 wherein the number of openings
in each of said paper layers is in the order of 100 to 1,000
openings per square inch and each of said openings has a diameter
of at least 0.072 of an inch.
Description
The present invention relates to an absorbent material and the
methods of making the same. While various applications for such
absorbent material are contemplated, the present invention finds
specific application for use in catamenial devices such as
tampons.
Tampons enjoy a wide acceptance and various catamenial devices have
been developed, employing various material compositions which must
provide a relatively high degree of absorbency in a product which
is relatively compact and economical to manufacture.
Aside from its absorbent characteristics, the material employed
must be comfortable so as to allow ready insertion into the vaginal
canal; have a strength sufficient to retain its integrity in use;
and further have the ability to expand once subjected to the
moisture in the vaginal canal so as to conform to the space between
the walls of the canal to prevent leakage of the menstrual
discharge and still allow for easy withdrawal.
The materials employed must also be adapted to be made economically
both with respect to material cost and manufacture processes.
Present catamenial devices generally employ fibrous materials such
as cellulosic structures, principally rayon, cotton, paper or
mixtures or blends thereof depending principally upon the
absorptive capacities of the bulk of the materials to increase
absorbency. Aside from varying the type of raw materials employed,
by and large developments to increase and/or enhance absorptive
capacity has been dealt with by either adding to the bulk of the
material and/or the compression of the materials so as to add
quantitatively to the mass of absorbent material within a given
volume.
As hereinafter more specifically described, a method has been found
to increase the absorbency levels of more economical, lesser
absorbent raw materials so as to enable the substitution of such
materials, in, for example a catamenial device, with the finished
product having an absorptive capacity which is at least at a parity
with a product of equal weight heretofore constructed of more
expensive, greater absorbent raw materials.
According to the present invention it has been found that
absorptive capacity is increased through the use in a tampon of an
absorptive material having at least two layers where at least one
of the layers has absorptive capabilities and at least one of the
layers includes filaments, wherein a portion of the filament of the
filament bearing layer has been transferred completely through
openings in the other companion layer.
It has been determined that particularly desirable results are
obtained if the two layers are dissimilar and where both layers are
absorbent materials. Further, one of the layers preferably is
adapted to act as a matrix with the filaments of the other of the
layers extending through openings in the matrix layer.
For example, a tampon having absorbent material weighing 2.2 grams,
50 percent of which is rayon and 50 percent of which is cellulose
crepe wadding normally has an absorbency equal to only 80 percent
of an identically constructed, more expensive all rayon tampon
having absorbent material weighing 2.2 grams.
If however, the same rayon and cellulose crepe wadding constituents
are modified in accordance with the present invention to provide
openings through the cellulose crepe wadding, and a plurality of
the filaments of the rayon are transferred through such openings
the tampon will have an absorbency level equal to the more
expensive all rayon tampon.
The absorptive composite of the present invention is preferably
formed by juxtaposing in substantially superimposed relationship,
two constituent materials; at least one of such materials being of
an absorptive substance, and at least one of such materials
including filaments; forming openings through at least one of such
materials, and transferring filaments from such filament bearing
material through the other of such materials.
Preferably the formation of the openings and the filament
transference steps are accomplished in a single operation by the
use of barbed needles, such as the type commonly referred to as
"felting needles" with a least portion of the barbs oriented along
the shank of the needle in the direction of the desired filament
transference.
In a tampon it is preferably that the transference of filaments be
of a degree such that the number of filaments on either face of the
matrix layer be substantially equal.
It is believed that the increase in absorbency of the material of
the present invention is due to alteration in the interstitial
spacing effected during transference, the increase of the surface
area effected in the creation of the openings, and/or the wicking
or capillarity between layers along the transferred through
filaments. The transferred through filaments act not only to
maintain the integrity of the united constituent materials but
further serve to maintain the integrity of the openings through the
layers. This latter feature has special pertinency in the use of
the absorbent material in catamenial devices where the forming
machinery generally exerts a crimping pressure on the material
being processed to shape and "set" the tampon.
Although such novel feature or features believed to be
characteristic of the invention are pointed out in the claims, the
invention and the manner in which it may be carried out may be
further understood by reference to the description following and
the accompanying drawings.
FIG. 1 is a top elevational view of an absorbent material of the
present invention, with a corner of one of the layers folded back
to indicate the manner in which the filaments of one layer are
transferred through the openings provided in the other layer.
FIG. 2 is a cross sectional view taken along lines 2--2 of FIG. 1
with dimensions exaggerated for clarity.
FIG. 3 is a cross sectional view, also exaggerated for clarity, of
another embodiment of the present invention.
FIG. 4 is a cross sectional view, similarly exaggerated for
clarity, of an alternate embodiment of an absorbent material of the
present invention.
FIG. 5 is a schematic illustration of an apparatus for constructing
an absorbent material in accordance with a method of the present
invention.
FIGS. 6 a- c are side elevations illustrating the sequential
filament transference of the present invention; FIG. 6a
illustrating superimposed layers of constituent material before the
entry of the transfer needle; FIG. 6b illustrating a transfer
needle as it transfers filaments; and FIG. 6c illustrating the
transfer needle as it is withdrawn from the united constituent
layers with the transferred filaments extending through the
openings.
FIGS. 7-9 are side elevational views of various transferring
needles which may be employed.
FIG. 10 is a sectionalized perspective of a portion of a tampon
employing absorbent material of the present invention.
FIG. 11 is a side elevation illustrating the absorbent material of
the present invention formed as a tampon and disposed within a
tampon insertion device, partially cut-away.
Referring now to the figures in greater detail, where like
reference numbers denote like parts in the various figures.
Illustrated in FIGS. 1 and 2 is one form of an absorbent composite
1 of the present invention. While various materials may be
employed, the particular composite shown comprises two dissimilar
constituents 2,3, both of which are absorbent, and at least one of
which (2) contains relatively long filaments. For example, one of
the constituents 2 is a fibrous substance, such as rayon and its
companion constituent 3 is an absorbent paper such as cellulose
crepe wadding.
As shown in FIGS. 1 and 2 the absorbent composite is provided with
a plurality of openings 4 extending through the cellulose crepe
wadding layer 3 through which the filaments 2' of the rayon fibrous
material 2 pass, such that filaments 2' and 2" extend on opposite
faces of the crepe wadding layer 3.
For clarity, the constituents 2,3 may be referred to as "layers"
although as illustrated in FIGS. 1 and 2, the transference of the
fiber filaments 2' of the fibrous material 2 through the companion
layer 3 has been accomplished in a manner so as to substantially
equalize the number of transferred filaments 2' and non-transferred
filaments 2" at the opposed faces of the companion layer 3.
In FIG. 3 the absorbent composite 5 illustrated also includes
dissimilar constituents with a fibrous layer 6 and a companion
matrix layer 7. However, a lesser portion 8 of the filaments of the
fibrous layer 6 are transferred through the openings 9 in the
companion matrix layer 7 so as to be exposed on the outer face of
the companion layer 7.
Whereas FIGS. 1-3 illustrate embodiments including two starting
"layers," various other combinations of multi-layers of material
are possible. In FIG. 4 for example there is illustrated an
absorbent composite 10 including an inner layer of fibrous material
11 and a pair of outer matrix layers 14. A portion of the filaments
12 of the inner layer 11 have been transferred through openings 13
in both outer superimposed layers 14.
It is to be appreciated that the "layers" of the absorbent
composite illustrated in FIGS. 1-4 are not necessarily as clearly
defined as illustrated. In the manufacture of such material the
filament transference is such that while the constituent materials
retain their respective identities a selective union of the
materials results visually integrating the constituents.
The amount of openings and filaments transferred per unit, can vary
depending upon the degree of increased absorbency desired ranging
from a small number of openings to that degree of openings which
would destroy the matrix layer. Since it is desired to have at
least some filaments passing through each of the openings to
maintain the integrity of the openings, a particularly favorable
union would be a uniting such as illustrated in FIG. 2 where there
is a substantial equalization of filaments on opposite faces of the
matrix layer. There is thus provided substantially equalized
wicking on both faces of the matrix with filaments extending
through all of the openings.
Referring to FIG. 5 there is illustrated an apparatus for
processing an absorbent composite in accordance with the present
invention.
A web of fibrous material 15 is fed such as from a spool 16 to a
needle punching machine 17. A second web of material 18 is also
fed, such as from a spool 19 so as to lie in superimposed
relationship with the fibrous material 15 when the two webs 15,18
are positioned at the work station area 20 of the needle punching
machine 17.
The needle punching machine 17 depicted is but a schematic
representation encompassing in a broad sense the basic operation of
needle punch equipment, it being understood that various apparatus
are available to perform the fiber filament transference and hole
punching functions requisite in forming the absorbent material of
the present invention. As illustrated, the needle punching machine
17 includes an reciprocally driven piston 21 adapted to drive a
needle beam 22 carrying a plurality of vertically oriented barbed
needles 23 so as to vertically actuate the needles 23 to vertically
reciprocate them into needle receptacles 24 in the bed 25. A
transference of the filaments and a union of the webs 15, 18 also
occurs and the so processed resultant absorbent material 27 is
taken up, such as by take-up spool 28.
As is more clearly illustrated in FIGS. 6a- c, the needles 23 pass
through the webs 15,18 effecting openings. The barbs 26 effect a
fiber filament transference from the fibrous web 15 through the
formed openings in the second web 18.
The orientation of the barbs and the stroke of the needles must be
such as to effect a transference, that is the barbs must pass
completely through the webs. The sequential steps are illustrated
in FIGS. 6a through 6c wherein the barbs 26 engage a portion of the
filaments on the web 15. The point of the needle 23 punctures the
web 18 and the filaments engaged by the barbs 26 are transferred
through the openings so made. The needle 23 is then retracted with
the filaments disengaged from the barbs, such filaments remaining
within the openings and extending through the web 18.
Various needle configurations are possible. In FIG. 7 for example
the needle 29 is constructed having barbs 30 disposed along its
shank 31 such that the barbs 30 would engage filaments and transfer
them in the direction of the arrow A. Such a needle configuration
would be employed where the shank 31 would first pass through the
fibrous material and then the transferee web such as is shown in
FIG. 5 and FIGS. 6a-c.
Were the web superimposition of FIG. 5 reversed, such as by having
the transferee web first subjected to the needle shank, a needle 32
such as illustrated in FIG. 8 would be suitable. The barbs 33 on
the needle 32 are aligned so as to engage a portion of the fiber
filaments on the fibrous web and draw such filaments through the
needle made openings in the transferee web. Or, in the alternative
in lieu of the unidirectional fiber filaments transference of FIG.
5, transference between webs can be accomplished from both above
and below the webs employing various combinations of needles 29,32
and 34 illustrated in FIGS. 7,8 and 9 respectively.
Further this multi-station, above and below technique may be
employed, where multiple webs are employed, such as the three webs
which initiate the absorbent material 10 shown in FIG. 4.
An alternative method of constructing a multi-layered composite
such as the composite of FIG. 4 may be accomplished by use of
needles, such as illustrated by the needle 34 of FIG. 9. The needle
34 of FIG. 9 includes along its shank 31, both barbs 36 for
transference in one direction and barbs 37 for transference in the
opposite direction. The downward stroke of the needle through the
multiple webs would transfer filaments in the direction of the
stroke through the bottom web. The reciprocal retracting motion of
the needle would transfer filaments from the central web of fibrous
material through the upper web.
Filament transference including the provision of openings has
resulted in increased absorbency and this has been found to be of
particular value in the construction of tampons. As illustrated in
FIG. 10, a typical tampon structure of the present invention is
shown.
The tampon illustrated may be constructed in a variety of ways
using various manufacturing techniques. For example, a multiphase
linear flow machine such as depicted in U.S. Pat. No. 3,465,390 to
Mooney may be employed.
The tampon 43 shown includes two layers of superimposed absorbent
material 38 constructed in accordance with the present invention. A
gauze layer 44 for strong securement is positioned between the two
absorbent material layers 38 and a withdrawal string 39 extends
through the layers 38, 44.
While a gauze layer 44 has been illustrated such gauze layer 44 may
be dispensed with in embodiments where the matrix layer of the
absorbent material 38 is of a sufficient strength to maintain the
string 39 securely even after the absorbent material 38 has been
subjected to moisture.
Illustrated in FIG. 11 is the tampon of FIG. 10 loaded into a
telescoping tube inserter device 40 such as those presently
available in the art. It might further be noted that as formed the
openings 41 and fibers 42 extend transversely with respect to the
body portion of the tampon thus facilitating not only the
absorption of menstrual fluid, but further present a network of
openings for the menstrual discharge.
As will be seen from the examples which follow, combined absorbent
and non-absorbent materials can be employed in the formation of an
acceptable starting material for use as a tampon and the
non-absorbent constituents may be chosen for both strength and
selective functionality. Further, enhancement of absorbent
characteristics is also provided in an all rayon combination.
The following test results are believed indicative of the enhanced
properties of an absorbent material constructed in accordance with
the present invention.
So as to provide more definitive results all of the following
samples were formed into tampons and absorbency levels were
determined in such condition. Each of the tampons tested had a
weight of approximately 2.4 grams with 2.2 grams being of absorbent
material and the remaining .2 grams including the intermediate
gauze layer. It is of note that in the making of the tampons
pressure is applied to the material surface to close some of the
openings in those samples (such as samples V and VI infra, where
the shortness of the filaments of the cellulose crepe wadding
prevented such filaments from maintaining the integrity of the
openings, thus accounting in some degree for the relatively minor
increment in absorbency levels.
Absorbency levels were tested employing the Syngyna Method. A
summary of the Syngyna Method may be found in a paper entitled "A
Comparison of the Absorptive Efficiency of the Commercial
Catamenial Tampons" written by Professor G.W. Rapp and published in
June 1958 (Dept. of Research, Loyola Univ., Chicago, Ill.)
The Syngyna Method basically consists of applying to a properly
positioned tampon an adaptation pressure of physiological magnitude
and then allowing a fluid of proper consistency to flow at its tip
at a controlled rate. The test is concluded when the first drop of
fluid begins to fall from the open end of the "Syngyna" regardless
of whether the tampon seems saturated or not.
Using as a control an all rayon tampon [weighing 2.4 grams] which
has a Syngyna absorbency level in grams of 11.2, the following
tests are exemplary of the present invention. The examples are
given by way of illustration and are not intended to limit the
invention.
---------------------------------------------------------------------------
I
Material Transference Employed Method Results
__________________________________________________________________________
50% rayon 3 Barbed needles, Syngyna absorbency denier, 1 9/16
triangular shank, of 11.2 grams fiber length 15 gauge (0.072 50%
cellulose inch) diameter crepe wadding 800 needle holes 10 lb. per
3,000 per square inch sq. feet (10 9 barbs per plies) needle
__________________________________________________________________________
---------------------------------------------------------------------------
II
Material Transference Employed Method Results
__________________________________________________________________________
50% rayon 3 NONE Syngyna absorbency denier, 1 9/16 of 9.0 grams
fiber length 50% cellulose crepe wadding 10 lb. wgt. per 3,000 sq.
feet (10 plies)
__________________________________________________________________________
The 50 percent rayon, 50 percent cellulose crepe wadding sample
exhibited progressively enhanced absorbency levels as the needle
transferring operation progressed as can be seen from the chart
below:
SYNGYNA ABSORBENCIES IN GRAMS
NO 100 400 800 Punches Punches Punches Punches Control 9.0 9.9 10.4
11.2 11.2
A further desirable result of the above two samples was discovered.
A single layer of cellulose crepe wadding (10lb. wgt. per 3,000 sq.
feet - 10 ply) alone was needle punched by the same needle punching
equipment of sample I. Such sampling started to loose its integrity
at approximately 800 punches per square inch whereas the same
material maintained its integrity when subjected to the same amount
of needle punches as part of the rayon-cellulose crepe wadding
union of sample I.
As can be noted from sample I above a more economical material,
that is cellulose crepe wadding has been substituted for a
substantial portion of the rayon in the tampon. Normally, as shown
in sample II this substitution would effect a 20 percent loss in
absorbency. However, as illustrated the material of sample I was
brought to the level of absorbency of an all rayon tampon of equal
weight.
---------------------------------------------------------------------------
III
Material Transference Employed Method Results
__________________________________________________________________________
40% rayon 3 Barbed needles, Syngyna absorbency denier, 1 9/16
triangular shank, of 10.40 grams fiber length 15 gauge (0.072 60%
cellulose inch diameter) crepe wadding 800 needle holes 10 lb. wgt.
per per square inch 3,000 sq. feet 9 barbs per needle (10 plies)
---------------------------------------------------------------------------
IV
Material Transference Employed Method Results
__________________________________________________________________________
25% rayon 3 Barbed needles, Syngyna absorbency denier, 1 9/16
triangular shank. of 9.30 grams fiber length 15 gauge (0.072 75%
cellulose inch) diameter crepe wadding 800 needle holes 10lb. wgt.
per per square inch 3000 sq. feet 9 barbs per needle (10 plies)
__________________________________________________________________________
---------------------------------------------------------------------------
V
Material Transference Employed Method Results
__________________________________________________________________________
100% cellulose Barbed needles Syngyna absorbency crepe wadding
triangular shank, of 8.8 grams 10 lb. wgt. per 15 gauge (0.072
3,000 sq. feet inch) diameter (10 plies) 800 needle holes per
square inch 9 barbs per needle
__________________________________________________________________________
It should be noted that a 100 percent cellulose crepe sampling
constituted of exactly the same materials of sample V. but not
subjected to the needle punching has a Syngyna absorbency of 8.6
grams. It is of interest to note that the fibers on such cellulose
crepe wadding are relatively short and non-elastic and thus
difficult to transfer through to another surface in great numbers.
---------------------------------------------------------------------------
VI
Material Transference Employed Method Results
__________________________________________________________________________
20% polyurethane Barbed needles, Syngyna absorbency 1/8 inch sheet
triangular shank of 10.10 grams (non-absorbent) 15 gauge (0.072 80%
cellulose inch diameter) crepe wadding 10 lb. 800 needle holes wgt.
per 3,000 sq. per square inch feet (10 plies) 9 barbs per needle.
__________________________________________________________________________
A polyurethane (non-absorbent) and cellulose crepe wadding sampling
containing no openings for filament transference exhibited an
absorbency level from 2 to 3 percent less than the sample VI
sampling above. It is also of note that where a sampling of 80
percent rayon [3 denier 1 9/16 fiber length] was combined in a 20
percent polyurethane [ 1/8 inch sheet non-absorbent] there was a 5
percent increment in absorbency where openings and filament
transference was effected by barbed needles of the type indicated
in the examples.
---------------------------------------------------------------------------
VII
Material Transference Employed Method Results
__________________________________________________________________________
15% cheese cloth Barbed needles, Syngyna absorbency 100% cotton;
85% triangular shank of 9.30 grams cellulose crepe 15 gauge (0.072
wadding 10 lb. wgt. inch diameter) per 3,000 sq. feet 800 needle
holes (10 plies) per square inch 9 barbs per needle
__________________________________________________________________________
A sampling of cheese cloth - cellulose crepe wadding similar to
example VII above not subjected to needle punching exhibited 25
percent less absorbency than the sample VII material.
As may be noted from the above, not only is there increased
absorbency (Samples I,III,IV,V) but materials heretofore not
generally employed in the manufacture of absorbent material,
especially as a constituent material, for a rather inexpensive item
such as a tampon (Sample VII) can be made to reach acceptable
absorbency levels for use in such products.
It has also been found that it is possible to increase the
absorbency of an all rayon tampon. Where the constituents are
layers weighing 2.2 grams of rayon, it has been found that the
needle punching operation (i.e., 800 strokes p.s.i. using a 15
gauge 0.072 diameter needle) spreads the filaments and realigns the
filament orientation with a resultant increase in absorbency
levels.
While all of the tests above were conducted employed 800 openings
per square inch, tests were conducted at varying levels from 10
openings per square inch to over 1,000 openings per square inch, it
being found that on the materials tested a range of between 600-850
punches per square inch gave best results.
In addition, increased absorbency occurs both in instances where
the constituent materials are the same and to a much greater degree
where the constituent materials are dissimilar. Similarly while
positive results have been obtained employing absorbent and
non-absorbent combinations, enhanced results occur where all of the
constituent materials are absorbent. All that is required however,
is that at least one of the layers be absorbent and at least one of
the layers contain filaments having a length sufficient to be
effectively transferred through the openings in one of the
constituent materials, at least to a sufficient degree to retain
the integrity of the openings.
Hence, the absorbency levels of the absorbent composite is a
function of:
a. the constituent materials
b. the size of the openings
c. the number of openings,
d. the number of filaments transferred
e. the denier of filaments, and
f. specific gravity (density) of filaments
By selectively varying any of the above such as by increasing the
needle size, and/or the number of barbs per needle, or increasing
the number of openings, or by otherwise affecting any of the above
variables, selective grading of absorbency levels can be
accomplished.
The only major limiting factor (aside from raw material cost) would
appear to be the ability of the constituents to withstand the
needle punching filament transference operation. As such, it is
desirable that the transferee layer be of a material which will act
well as a matrix to retain openings having filaments extending
therethrough.
While the present invention has been described with particularity
in terms of its application to a tampon various other uses are
possible. It is to be further appreciated that the terms and
expressions which have been employed are used for purposes of
illustration, it is recognized though that various modifications
are possible within the scope of the invention as claimed.
* * * * *