2. Description of the Prior Art The barrel of present commercial tampons having a plastic applicator are typically manufactured as one-piece molded objects, such as those of Kotex Security tampons and Playtex Gentle Glides tampons. The barrel of present commercial cardboard applicator tampons are formed from either convolutely wound cardboard, such as o. b. applicator tampons, or spiral- wound cardboard, such as Tampaxe tampons.

In order to improve comfort during use, an applicator may be formed with petals on the insertion end of the applicator. Additionally, some applicators have a fingergrip and a plunger of a diameter reduced from that of the applicator barrel. This feature has been found not only to render the tampon applicator more grippale, but it is also more aesthetically preferred by consumers.

For current reduced diameter fingergrip tampon applicators, the tampon pledget must be loaded into the insertion end of the applicator due to the smaller opening at the fingergrip end. As a result, these tampons are restricted from bottom or plunger end loading of the absorbent pledget. This requires the petals of the applicator, if any, to be post-formed to their final shape after the pledget has been loaded with an absorbent pledget. Post- forming of petals requires the material to be plasticized. Typically, plastic petals are plasticized by heat and are shaped by the use of an external forming die.

Cardboard petals are more difficult to plasticize and require the

additional use of an internal mandrel. Usual methods involve heating the tip to volatilize the water (either existing or supplemental moisture) and then forcing the petal into shape using an internal mandrel in conjunction with the external die. The internal mandrel has a diameter that is approximately the same as the barrel, and consequently would not be able to enter through a reduced diameter fingergrip area. Thus, the necessity of the internal mandrel to shape the petal tip has precluded the manufacture of a reduced diameter fingergrip area on a cardboard applicator.

With current tampon assembly methods, it is only feasible to have one highly enlarged plunger end prior to assembly of the plunger into the barrel, because the other end of the plunger must fit through the fingergrip area, whether the plunger is inserted into the applicator through the bottom or the top of the barrel. The plunger end that fits through the fingergrip area can be flared after applicator assembly, but this approach limits the design possibilities of the flare and increases manufacturing difficulties.

Therefore, there is a need for a tampon applicator, and more particularly a cardboard applicator, having a reduced diameter fingergrip and/or plunger that can be manufactured such that petals can be pre-formed or integrated on the insertion end of the applicator barrel, prior to loading an absorbent pledget into the applicator barrel.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a tampon applicator adapted to allow an absorbent pledget to be side or laterally loaded into the barrel of the applicator.

It is another object of the present invention to provide such a tampon applicator having petals pre-formed on the insertion end of the applicator barrel.

It is still another object of the present invention to provide such a tampon applicator having a fingergrip.

It is a further object of the present invention to provide such a tampon applicator having a fingergrip with a reduced diameter compared to the diameter of the applicator barrel.

It is still a further object of the present invention to provide a method of making a tampon applicator having an absorbent pledget laterally loaded into the barrel of the applicator.

These and other objects and advantages of the present invention will be appreciated by a tampon applicator adapted to allow an absorbent pledget to be laterally loaded into the barrel of the applicator. By laterally loading the pledget, the applicator may include pre-formed petals on the insertion end of the barrel and/or a fingergrip having a reduced diameter. The applicator may be formed from any suitable material, such as, for example, biopolymer, paper, paperboard, paper slurry, plastic, thermoplastic polymers, thermosetting polymers, or any combinations thereof.

DESCRIPTION OF THE DRAWINGS Fig. 1 is a plan view of an assembled tampon applicator according to all embodiments of the present invention; Fig. 2 is a plan view of a two-piece, movably connected tampon applicator barrel according to one embodiment of the present invention; Fig. 3 is an end view of the insertion end of the tampon applicator barrel of Fig. 2; Fig. 4 is a plan view of a two-piece, non-connected tampon applicator barrel according to a second embodiment of the present invention ; Fig. 5 is an end view of the insertion end of the tampon applicator barrel of Fig. 4; Fig. 6 is a plan view of the tampon applicator of Fig. 2 with a plunger positioned in one piece of the two-piece barrel ; Fig. 7 is a plan view of the applicator barrel of Fig. 4 with a plunger positioned in one piece of the two-piece, non-connected applicator barrel ;

Fig. 8 is a plan view of the tampon applicator of Fig. 6 with an absorbent pledget laterally loaded into one piece of the two-piece, movably connected applicator barrel ; and Fig. 9 is a plan view of the tampon applicator of Fig. 7 with an absorbent pledget laterally loaded into one piece of the two-piece, non- connected barrel.

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a formed applicator barrel that is adapted to be laterally loaded with an absorbent pledget, i. e. the pledget is loaded through neither the insertion end or the removal end of the applicator, but rather is placed inside a barrel that is at least partially opened along one side. The formed applicator barrel may also include pre-formed petals on the insertion end of the applicator barrel and/or a fingergrip on the removal end of the applicator.

By forming the applicator in this manner, it allows for many adjustments to be made to the applicator in particular, and the tampon as a whole, that are not possible with the current approaches to forming applicators and loading pledges. For example, it allows the petals to be pre-formed and the fingergrip to have a reduced diameter simultaneously because it eliminates the need for an opening in the end of the applicator large enough to accept the pledget.

It is believed that reduced diameter fingergrips are perceived by consumers to be more grippale and aesthetically preferred. Pre-formed petals are favored from a production standpoint since more accuracy and symmetry is ensured. Also, some materials, such as paper slurry, are resistant to post-forming and require the use of an internal mandrel, which is currently difficult in conjunction with a reduced diameter fingergrip.

Incorporating pre-formed petals with a reduced diameter fingergrip creates an optimal combination of aesthetics and quality.

Referring to Fig. 1, an assembled tampon applicator according to the present invention is represented by reference numeral 10. The applicator 10

has a barrel or applicator barrel 12 with a plunger end 18 and an insertion end 20, and a plunger 24. The barrel 12 is formed such that a pledget 22 is side or laterally loaded in the barrel. It is preferred that assembled applicator barrel 12 have petals 16 pre-formed on insertion end 20 to enhance user comfort.

Typically, applicator barrel 12 will have about two to about twelve petals 16 pre-formed on insertion end 20. More preferably, applicator barrel 12 will have about two to about six pre-formed petals 16. Applicator 10 may also have a reduced diameter fingergrip 14 and, preferably, plunger 24 also has a reduced diameter. Pledget 22 has a removal string 32.

Referring to Figs. 2 and 3, one embodiment of the applicator barrel 12 of the tampon applicator of the present invention is depicted. Applicator barrel 12 may be a single molded barrel having a first barrel portion 34 and a second barrel portion 36, which is essentially a mirror image of and similar in shape to barrel portion 34. When the first barrel portion 34 and second barrel portion 36 are combined or connected, they form a cross-section that may be generally circular, ovoid, elliptical, or any combinations thereof. First barrel portion 34 is movably connected to second barrel portion 36 by one or more connectors 38 along one side of each barrel portion. Suitable connectors 38 include, for example, a mechanical hinge, a living hinge, or any combinations thereof. Preferably, one or more connectors 38 is a living hinge, akin to a clamshell.

Each barrel portion 34,36 preferably has pre-formed petals 16 that enhance user comfort during insertion of the assembled applicator 10. The total number of petals desired on the assembled applicator 10 can be divided between first barrel portion 34 and second barrel portion 36 in any manner.

Also, for greater ease of insertion, first barrel portion 34 and second barrel portion 36 both have a reduced diameter fingergrip 14 integrally formed at plunger end 18 of barrel portions 34,36 of applicator 10.

Referring to Figs. 4 and 5, in a second embodiment of the tampon applicator of the present invention, applicator 10 has a first barrel portion 34 and a separate, non-connected second barrel portion 36. Preferably, second

barrel portion 36 is essentially the mirror image of first barrel portion 34. In addition, each barrel portion 34,36 has petals pre-formed on insertion end 20.

Again, for greater ease during insertion of applicator 10, first barrel portion 34 and second barrel portion 36 both have a reduced diameter fingergrip 14 integrally formed at plunger end 18.

The grippability of fingergrip 14 may be enhanced by forming at least one gripping structure, and preferably a plurality of gripping structures, in or on the outer surface of fingergrip 14. Fingergrip 14 may be textured in addition to having at least one gripping structure.

The gripping structures may be molded or formed in any number and/or configuration suitable for creating enhanced grippability of tampon applicator 10. The gripping structures may be molded such that they extend above the outer surface of fingergrip 14, they extend below the outer surface of the fingergrip, the tip or upper edge of the gripping structure is aligned with the outer surface of the fingergrip, or any combinations thereof. Suitable shapes or configurations for gripping structures include, for example, one or more arcs, circles, concave, cones, convex, diamonds, grooves, lines, louvers, ovals, polygons, protuberances, rectangles, ribs, slits, squares, treads, triangles, or any combinations thereof.

Referring to Figs. 6 and 7, the tampon applicator barrels 12 of Figs. 2 and 4 are now depicted with plunger 24 positioned in first barrel portion 34.

Plunger 24 has a pledget-contacting end 26 and a free or removal end 28. It is an advantage of the present invention to be able to modify the dimensions of the ends of plunger 24. For example, increasing the size of pledget- contacting end 26 of plunger 24 is useful because it distributes the force from the plunger over a larger area of the pledget, which is especially useful if the pledget is not rigid. Having plunger 24 with a pledget-contacting end 26 that is larger than that of the base opening of barrel 12 is also beneficial because it prevents separation of the plunger from the barrel, a point of frustration for many consumers.

Preferably, removal end 28 is a flared end. A flared removal end

provides the benefit of a comfortable finger-rest during insertion of tampon applicator 10. With the open-sided barrel 12 of the present invention, plunger 24 is placed inside applicator 10 prior to forming assembled barrel 12, enabling both plunger ends 26,28 to have an increased size or flare, as well as the barrel having a reduced diameter fingergrip and pre-formed petals.

Referring to Figs. 8 and 9, the tampon applicator assembly of Figs. 6 and 7 are now depicted with absorbent pledget 22 laterally or side loaded into first barrel portion 34. After laterally loading absorbent pledget 22, first barrel portion 34 and second barrel portion 36 are connected and secured together.

There are several possibilities for connectably securing first barrel portion 34 with second barrel portion 36. Suitable connectors include, for example, adhesive, melt welding, snapping the pieces together (i. e. interference fit), or any combinations thereof. Preferably, the first and second barrel portions 34,36 are secured by an adhesive.

The side-loaded tampon applicator 10 may be formed from any formable material known in the art. Suitable formable material includes, for example, biopolymer, paper, paperboard, paper slurry, plastic, thermoplastic polymer, thermosetting polymer, or any combinations thereof.

In addition to incorporating a reduced diameter fingergrip 14 with pre- formed petals 16, it is possible to form applicator 10 in a shape that would otherwise be impossible to create in conjunction with a reduced diameter fingergrip and/or pre-formed petals. By way of example, barrel 12 itself may be tapered towards the tip or insertion end 20, or it could have varying diameters throughout its entire length. The cross-section of the barrel may be, for example, circular, ovoid, elliptical, or any combinations thereof. These more complex designs offer possibilities that are precluded by the standard forming processes, since the mold mandrel would not have to be removed through a smaller opening.

This method of barrel formation also provides the ability to create a more intricate surface topography. For example, any variety of size, shape, style, and number of protuberances can be formed into the applicator, creating

both internal and external features. These features could include ridges inside the barrel that reduce the contact area between the barrel and plunger and the barrel and pledget, thus reducing ejection force.

A laterally loaded or side loaded barrel 12 allows for modifications to and treatments of the barrel itself, which are more difficult to execute with current molding techniques. With the inner surface of barrel 12 exposed during the tampon assembly process, it becomes easier to incorporate surface treatments into the production process. For example, the inner surface of barrel 12 may be treated with a friction-reducing coating, or with microcapsules containing fragrance, lubricant, medicinal composition, or other materials that would be activated when pledget 22 was expelled from applicator 10.

Suitable surface treatment materials for treating any surface of barrel 12 and/or plunger 24 to enhance strength and/or reduce surface friction include, for example, cellophane, cellulose, epoxy, lacquer, nitrocellulose, nylon, plastic, silicone, polyester, polylactide, polyolefin, polyvinyl alcohol, polyvinyl chloride, wax, or any combinations thereof.

The present invention having been thus been described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined in the appended claims.