Abstract: The present invention relates to an intravaginal tampon for feminine hygiene includes a generally cylindrical absorbent pledget and a withdrawal element operatively connected to the generally cylindrical pledget proximate to the withdrawal end thereof. The absorbent pledget includes a mass of fibers compressed into a self sustaining shape and a sheet-like fluid-permeable cover substantially enclosing the mass of fibers. The absorbent pledget has formed thereon or therein at least one continuous groove form comprising a plurality of substantially longitudinal groove segments linked only to form a turn located alternatively proximate the insertion end and withdrawal end and wherein the continuous groove form extends around at least 180° about the circumference of the generally cylindrical absorbent pledget.

Abstract: A packaged elongate intravaginal device has an overwrap substantially enclosing the device. The overwrap has a longitudinal overlap seam disposed generally parallel to the longitudinal axis. The seam includes one ply of overwrap material disposed at a first margin of a overwrap blank superposed on a second ply of overwrap material disposed at a second margin of the overwrap blank, opposite the first. The overwrap has a substantially continuous line of weakness that intersects a plane including the longitudinal axis of the packaged device at at least three unique locations. The line of weakness extends across the longitudinal overlap seam and includes weakness components superposed in each ply of the overlap seam, and the line of weakness is arranged and configured in a manner to permit the overwrap to remain as a unitary structure upon destruction of the line of weakness.

Abstract: An intravaginal device has a fluid storage element and at least one fluid transport element in fluid communication with the fluid storage element. It is produced by providing an individual sheet of material having properties useful to move bodily fluids, attaching the individual sheet to a substantially cylindrical fluid storage element to form the at least one fluid storage element, folding the fluid storage element, and packaging the resultant device. The at least one fluid transport element is capable of extending radially away from the fluid storage element during use. The invention also includes alternative methods of forming the intravaginal device.

Abstract: A packaged elongate intravaginal device has an overwrap substantially enclosing the device. The overwrap has a longitudinal overlap seam disposed generally parallel to the longitudinal axis. The seam includes one ply of overwrap material disposed at a first margin of a overwrap blank superposed on a second ply of overwrap material disposed at a second margin of the overwrap blank, opposite the first. The overwrap has a substantially continuous line of weakness that intersects a plane including the longitudinal axis of the packaged device at at least three unique locations. The line of weakness extends across the longitudinal overlap seam and includes weakness components superposed in each ply of the overlap seam, and the line of weakness is arranged and configured in a manner to permit the overwrap to remain as a unitary structure upon destruction of the line of weakness.

Abstract: An intravaginal device has a fluid storage element and at least one fluid transport element in fluid communication with the fluid storage element. The at least one fluid transport element has a first plate and a second plate coupled to the first plate. The second plate is capable of separating from the first plate sufficiently to provide inter-plate capillary action. The at least one fluid transport element is bendable about an axis substantially parallel to the longitudinal axis of the fluid storage element. The invention also includes methods and apparatus useful in the production of an intravaginal device.

Abstract: A process for overwrapping a catamenial device such as a tampon includes the steps of providing a substantially cylindrical overwrapper material, inserting a catamenial device into the overwrap material, and closing the open end of the overwrapper material. The overwrapper material has an open end, a closed end, and a first length. The catamenial device has a tapered insertion end, a longitudinal axis, and a length less than the first length, such that the open end of the overwrapper material extends beyond the insertion end of the inserted catamenial device. Concave clamping jaws are applied to the open end of the overwrapper material to urge it toward the longitudinal axis of the catamenial device; to conform portions of the overwrapper material to the insertion end of the catamenial device; and to fold overwrapper material between adjacent clamping jaws to form fins extending outwardly from the conformed portions.

Abstract: An intravaginal device has a fluid storage element and at least one fluid transport element in fluid communication with the fluid storage element. The at least one fluid transport element has a first plate a second plate coupled to the first plate. The second plate is capable of separating from the first plate sufficiently to provide inter-plate capillary action. The at least one fluid transport element is bendable about an axis substantially parallel to the longitudinal axis of the fluid storage element. The fluid transport element may substantially envelop the fluid storage element, and it may be attached to the withdrawal end of the fluid storage element, on at least one longitudinal side of the fluid storage element, to itself proximate the withdrawal end of the fluid storage element, and/or to the withdrawal string.

Abstract: Apparatus for producing an intravaginal device includes a forming tool having an aperture, a male tool having a plurality of forming blades arranged radially about an aperture, at least one bonding element, and at least one moveable pushrod. The forming tool includes a holding plate having a plurality of vacuum ports, and the aperture of the forming tool is located in the forming plate. The aperture of the forming tool has a plurality of slots connected to and extending therefrom. The bonding element is moveable toward the aperture in the forming tool. The apertures are aligned along a machine axis to permit the pushrod to move a fluid storage element through each aperture, the forming blades of the male tool are aligned with the slots of the forming tool, and guide edges of the forming blades accommodate a fluid storage element aligned with the aperture of the male tool.

Abstract: A method and apparatus for manufacturing absorbent tampons with reduced fiber fluff includes a novel needlepunching unit. The method includes the steps of providing a continuous nonwoven fibrous web; separating individual nonwoven web sections from the continuous nonwoven fibrous web; forming distinct side edges of each individual nonwoven web section; rolling the nonwoven web section to form a substantially cylindrical tampon blank; and compressing the substantially cylindrical tampon blank to form the absorbent tampon. The distinct side edges of each individual nonwoven web section are formed by needlepunching proximate the longitudinal side edges of each individual nonwoven web section, folding both longitudinal side edges inwardly to form distinct side edges of the individual nonwoven web section, and needlepunching the folded longitudinal side edges to stabilize the distinct side edges of the individual nonwoven web section.

Abstract: An intravaginal device has a fluid storage element and at least one fluid transport element in fluid communication with the fluid storage element. The at least one fluid transport element has a first plate and a second plate coupled to the first plate. The second plate is capable of separating from the first plate sufficiently to provide inter-plate capillary action. The at least one fluid transport element is bendable about an axis substantially parallel to the longitudinal axis of the fluid storage element. The invention also includes methods and apparatus useful in the production of an intravaginal device.

Abstract: An intravaginal device has a fluid storage element and at least one fluid transport element in fluid communication with the fluid storage element. The at least one fluid transport element has a first plate and a second plate coupled to the first plate. The second plate is capable of separating from the first plate sufficiently to provide inter-plate capillary action. The at least one fluid transport element is bendable about an axis substantially parallel to the longitudinal axis of the fluid storage element. The invention also includes methods and apparatus useful in the production of an intravaginal device.

Abstract: An intravaginal device has a fluid storage element and at least one fluid transport element in fluid communication with the fluid storage element. The at least one fluid transport element has a first plate and a second plate coupled to the first plate. The second plate is capable of separating from the first plate sufficiently to provide inter-plate capillary action. The at least one fluid transport element is bendable about an axis substantially parallel to the longitudinal axis of the fluid storage element. The invention also includes methods and apparatus useful in the production of an intravaginal device.

Abstract: A packaged elongate intravaginal device has an overwrap substantially enclosing the device. The overwrap has a longitudinal overlap seam disposed generally parallel to the longitudinal axis. The seam includes one ply of overwrap material disposed at a first margin of a overwrap blank superposed on a second ply of overwrap material disposed at a second margin of the overwrap blank, opposite the first. The overwrap has a substantially continuous line of weakness that intersects a plane including the longitudinal axis of the packaged device at at least three unique locations. The line of weakness extends across the longitudinal overlap seam and includes weakness components superposed in each ply of the overlap seam, and the line of weakness is arranged and configured in a manner to permit the overwrap to remain as a unitary structure upon destruction of the line of weakness.

Abstract: An intravaginal device has a fluid storage element and at least one fluid transport element in fluid communication with the fluid storage element. The at least one fluid transport element has a first plate and a second plate coupled to the first plate. The second plate is capable of separating from the first plate sufficiently to provide inter-plate capillary action. The at least one fluid transport element is bendable about an axis substantially parallel to the longitudinal axis of the fluid storage element. The invention also includes methods and apparatus useful in the production of an intravaginal device.

Abstract: A process for overwrapping a catamenial device such as a tampon includes the steps of providing a substantially cylindrical overwrapper material, inserting a catamenial device into the overwrap material, and closing the open end of the overwrapper material. The overwrapper material has an open end, a closed end, and a first length. The catamenial device has a tapered insertion end, a longitudinal axis, and a length less than the first length, such that the open end of the overwrapper material extends beyond the insertion end of the inserted catamenial device. Concave clamping jaws are applied to the open end of the overwrapper material to urge it toward the longitudinal axis of the catamenial device; to conform portions of the overwrapper material to the insertion end of the catamenial device; and to fold overwrapper material between adjacent clamping jaws to form fins extending outwardly from the conformed portions.

Abstract: A method of folding a plurality of flexible elements about a central fluid storage element includes of urging an intravaginal device into a folding device; imparting relative rotation between at least a portion of the folding device and the intravaginal device; and contacting the plurality of flexible extensions with the folding device. Wherein the intravaginal device includes a fluid storage element and a plurality of flexible extensions extending therefrom, and the flexible extensions are folded about the fluid storage element in a uniform direction. Alternatively, in place of relative rotation, the flexible extensions are folded by means of guide rails of the folding device. Several apparatus may be employed in this and related methods.